Rapid robotic handling of mold parts used to fabricate contact lenses

ABSTRACT

A method for removing and transporting ophthalmic lens fabricating mold sections from a molding device to an inert chamber in a predetermined time, controlled by a central processor. The method includes starting a timer upon opening the molding device and exposing the mold sections; actuating a robotic arm to transport the mold sections from the molding device to an intermediate position using a compound movement; actuating a cam-controlled arm to transport the mold sections from the intermediate position to a pallet held on a conveyor belt at a cam-arm pre-part release location; and releasing the pallet to move on the conveyor belt to the inert chamber for continued transport of mold containing pallets to a treatment or processing facility for producing and/or packaging of the contact lenses.

CROSS REFERENCES

This is a divisional application of a U.S. patent application Ser. No.08/869,833 filed on Jun. 5, 1997 new issued as U.S. Pat. No. 6,007,229issued on Dec. 28, 1999 and claims a benefit of the filing date of thatapplication.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates, in general, to a method for rapid robotichandling of small articles removed from molds. More specifically, thepresent invention pertains to such a method which is particularly wellsuited for removing the articles from a molding machine having molds inwhich they are molded, and thereafter carrying the articles within avery short period of time away from the molds and depositing thearticles for further processing in a high speed, automated productionsystem.

2. Description of the Prior Art

Recently, attention has been directed by industry toward economicallyforming large quantities of high-quality contact lenses in a preciselyoperating, high-speed automated molding system. In such a lens moldingsystem, each lens is formed by sandwiching a monomer in an interspacewhich is present between front and back mold sections, normallyidentified as, respectively, front and base or back curves. The monomeris polymerized to form a contact lens, which is then removed from themold sections, further treated and then packaged for consumer use.

The mold sections used in the above-mentioned process may themselves beformed through the intermediary of injection molding or compressionmolding processes. These mold sections may be made the family ofmaterials consisting of thermoplastics; for example, preferably such aspolystyrene, which has been determined to constitute an excellentmaterial for making these mold sections. Polystyrene does not chemicallyreact with the hydrophilic material normally employed to make thecontact lenses; for instance, such as hydroxy ethylene methacrylate(HEMA). Therefore, it is possible to form very high quality contactlenses of that type of material in polystyrene molds. In addition,polystyrene is widely available in industry and commerce and, as aresult, is relatively inexpensive. Because of the ease and low cost withwhich polystyrene mold sections may be produced and then employed tomold contact lenses, each pair of complementary front and base curvepolystyrene mold sections is typically used only a single time in orderto mold only one contact lens, and may then be discarded or recycled forother uses.

In the above-discussed automated contact lens production system, it isdesirable to eliminate or to minimize any exposure to oxygen of thehydrophilic monomer used for the manufacture of the contact lenses.Correspondingly, it is desirable to eliminate or minimize the exposureof the lens mold sections to oxygen. Therefore, when the polystyrenemold sections are formed and then used for the purpose of making contactlenses in the above-discussed manner, it is desirable to rapidlytransfer these mold sections from the mold in which they are made to alow oxygen (preferably nitrogen) environment. It has been difficult toachieve the desired transfer speed with conventional robot assemblies orcontrols because presently available robots do not move with adequaterapidity and precisely enough to enter into, and exit from, the moldingapparatus at the desired rate of speed in effectuating the removal ofthe molded articles. In particular, if these robots are operated at thenecessary rate of speed, they tend to waffle and shake or vibrateundesirably as they come to a sudden stop, and the movements of therobot are resultingly not sufficiently precise. On the other hand, ifthe robots are slowed down so as to be able to move more precisely, therobots no longer possess the desired speed to facilitate the contactlens mass-producing process.

Moreover, in the above-mentioned automated contact lens productionsystem, the contact lens mold sections may not be fully solidified whenthey are ejected or removed from the mold in which they are formed. Itis, therefore, important that any robot or apparatus which is used tocarry the contact lens-forming mold sections away from that mold willnot interfere so as to adversely affect the desired optical qualities ofthe contact lens mold sections. In particular, it is important that anysuch robot or apparatus be capable of absorbing the kinetic energy ofthe lens mold sections as they are being transferred to suchtransporting robot or apparatus without deleteriously altering theshape, form or dimensions of the lens mold sections. The robot and moldtransfer method employed must, likewise, be able to transport the lensmold sections in a manner that permits those lens mold sections to cooland completely harden in a desired manner.

In addition, in order to maximize the optical quality of the contactlenses, it is preferred that the optical surfaces of the front and basecurve polystyrene mold sections; that is, the surfaces of those moldsections which touch or lie against the hydrophilic monomer as the lenspreform is being molded, not be engaged or contacted by any mechanicalhandling equipment while the mold sections are being transported by andpositioned in the lens molding system.

In order to achieve the foregoing kind of transport system, pursuant tothe disclosure of copending U.S. patent application Ser. No. 08/258,267,continued as U.S. patent application Ser. No. 08/757,154, now issued asU.S. Pat. No. 5,681,138, there is described an apparatus for removingand transporting ophthalmic or contact lens mold sections from a mold,and which generally comprises first, second and third assemblies. Thefirst assembly removes the lens mold sections from the mold andtransports the lens mold sections to a first location, the secondassembly receives the lens mold sections from the first assembly andtransports the lens mold sections to a second location, and the thirdassembly receives the lens mold sections from the second assembly andtransports the lens mold sections to a third location. Preferably, thefirst assembly comprises a hand including vacuum structure to receivethe lens mold sections from the mold and to releasably hold the lensmold sections, and a support subassembly connected to the hand tosupport the hand and to move the hand between the mold and the firstlocation.

The second assembly preferably includes a support frame, a platform toreceive the lens mold sections from the first assembly and supported bythe support frame for movement between the first and second locations,and moving means for moving the platform along the support frame andbetween these first and second locations.

The preferred design of the third assembly includes a transportsubassembly and a support column. The transport subassembly receives thelens mold sections from the second assembly, releasably holds those lensmold sections, and carries the lens mold sections to the third location;and the support column supports the transport subassembly for movementbetween the second and third locations.

In an effort designed to simplify and provide further improvements onthe foregoing transport apparatus, alternative embodiments have beendeveloped more recently, as disclosed in copending U.S. patentapplication Ser. No. 08/431,884, continued as U.S. patent applicationSer. No. 09/048,859, now issued as U.S. Pat. No. 5,980,184, whichdiscloses an apparatus for removing and transporting articles, such asophthalmic contact lens mold sections, or primary contact lens packagingelements, such as the base members of blister packages, from a mold. Theapparatus, in one embodiment thereof, which is employed in themanufacture of lens mold base curves, includes first, second, and thirdassemblies; the first of which removes the articles from the moldingstation at a first location and transports them to a second location;the second assembly receives the articles from the first assembly andtransports them to a third location, and the third assembly receives thearticles from the second assembly and transports them to a fourthlocation.

A second embodiment of the apparatus which is used in the forming oflens mold front curves additionally includes a flipper assembly disposedbetween the first and third assemblies, which flipper assembly receivesthe articles from the first assembly and inverts them before depositingthem onto the third assembly. This second embodiment is useful inconjunction with molded articles which are transported to the flipperassembly in an inverted position.

A third embodiment, which produces primary packaging components, such asthe base members of blister packages for housing the contact lenses,includes second and third assemblies which further include means foraltering the relative spacing between the articles while the articlesare being transported.

Although the foregoing embodiments and operative versions of theapparatus, as elucidated in the aforementioned copending U.S. patentapplications, are employable in providing the molded componentsconstituting mold sections for forming contact lenses, and also primarypackage elements for contact lenses, such as the contact lens-receivingbase members of blister packages, there are problems associated withvibration, speed and rejection of molded components overly exposed tooxygen. The numerous operating and transfer assemblies and stationswhich are required for transporting the molded components at high ratesof speed from the molding installation in which they are formed to theirultimate depositions onto pallets for further treatment, such as in alow oxygen or nitrogen atmosphere, are of considerable complexity,subject to waffling and vibration and rendering the efficacy ofproducing acceptable articles difficult to maintain as a result of themultiplicity of operative apparatus components, and transfer andtransport paths employed in the various apparatus embodiments. Forexample, numerous programmable logic controllers (PLCs) used toindividually control various sections of the assemblies and stationsprevent increasing operating speeds and reducing oxygen exposure time.This is due, for example, to the time needed for the PLCs to communicatewith each other or with other PLCs of downstream or upstream assemblies.

SUMMARY OF THE INVENTION

Pursuant to the present invention, there is contemplated a simplifiedmethod that increases speed of operation of assemblies for transferringand transporting high quality articles which have been molded, such ascontact lens mold sections and primary package elements for contactlenses. This is achieved by replacing various programmable logiccontrollers (PLCs) by a supervisory microprocessor that increasescommunication and synchronization between the molding apparatus and anultimate conveyance element, such as a pallet, for transporting thesemolded articles into a nitrogen or low oxygen environment or otherdesired location for further processing.

The object of the present invention is to provide a computer controlledmethod for removing and transporting ophthalmic lens fabricating moldsections from a molding device to an inert chamber in a predeterminedtime that eliminates the problems of conventional methods.

Another object of the present invention is to provide a method thateliminates various programmable logic controllers (PLCs).

Yet another object of the present invention is to provide a method thatreduces response time in processing molded components, and quicklydetermining and discarding unacceptable molded components withoutdisrupting the continuous operation of assemblies, including upstreamand downstream assemblies.

A further object of the present invention is to provide a method thatincludes rapid communication with upstream and downstream assemblies,and precise high speed, as well as vibration and shock free, movement totransfer among the various assemblies molded articles, which may not yetbe completely cured or hardened, without causing undue plasticdeformations of the articles.

A still further object of the present invention is to provide a methodthat includes multi-tasking, where various tasks are controlled by asupervisory microprocessor.

An additional object of the present invention is to provide a methodthat accurately determines total oxygen exposure time to correctlyreject overly exposed mold components, and rapidly remove and transportarticles made from the family of thermoplastics, such as polystyrene,from a mold in which those articles are made through the intermediary ofsophisticated robotics, into a low oxygen environment of an automatedcontact lens molding system, within a period or time interval of only afew seconds.

A still further object of the present invention is to provide a methodthat removes a plurality of discrete molded articles from a mold withthe molded articles arranged in a matrix array, and to selectivelyeither preserve that matrix array during subsequent handling of themolded articles, or reorient the matrix and the relative spacing of themolded articles therein according to a second predetermined matrix priorto being transported to a further locale.

These and other objects of the inventions are achieved by a method by acentral processor controlled for removing and transporting ophthalmiclens fabricating mold sections from a molding device to an inert chamberin a predetermined time comprising the steps of:

starting a timer upon opening the molding device and exposing the moldsections;

actuating a robotic arm to transport the mold sections from the moldingdevice to an intermediate position;

actuating a cam-controlled arm to transport the mold sections from theintermediate position to a pallet held on a conveyor belt at a cam-armpre-part release location; and

releasing the pallet to move on the conveyor belt to the inert chamber.

A further step includes identifying molded articles as unacceptable whenthe pallet enters the inert chamber in a time that exceeds thepredetermined time.

The robotic arm actuating step includes the steps of:

accelerating the robotic arm along a curvilinear path from a waitingposition to an opening in the molding device in a synchronism with theopening of the molding device, in accordance with accelerationparameters stored in a memory of a central processor; and

decelerating the robotic arm after an acceleration time stored in thememory, where the robotic arm is approximately in the opening of themolding device, to provide a damping effect for allowing transfer of themold sections from the molding machine to the robotic arm.

A further embodiment includes the steps of:

generating control parameters for a plurality of motors to effectuate acurvilinear motion of the robotic arm between the waiting position andthe opening of the molding device;

storing the control parameters in the memory of the central processor;

opening the molding device and exposing the mold sections;

accelerating the robotic arm along a curvilinear path from the waitingposition to the opening in the molding device in a synchronism with theopening of the molding device, in accordance with the control parametersstored in the memory; and

decelerating the robotic arm when the robotic arm is approximately inthe opening of the molding device, to provide a damping effect forallowing transfer of the mold sections from the molding machine to therobotic arm.

Illustratively, the control parameters for each of the motors includeacceleration and deceleration parameters, and acceleration anddeceleration time parameters.

Additional steps includes raising a nest to receive the mold sections atthe intermediate position; lowering the nest after transfer thereon ofthe molded sections from the robotic arm; and transferring the moldedsections from the lowered nest to the cam-controlled arm. A further stepincludes, in the case the mold sections are primary package molds forexample, actuating cylinders to rotate and resize the mold sections.

The cam-controlled arm movement includes moving the cam-controlled armto the intermediate position; lowering the cam-controlled arm to pickthe molded sections from a nest that receives the mold sections from therobotic arm; raising the cam-controlled arm up to the intermediateposition after picking the molded sections from the nest; moving thecam-controlled arm to the pallet; lowering the cam-controlled arm whileraising the pallet from the cam-arm pre-part release location to acam-arm part release location; and transferring the molded sections fromthe cam-controlled arm to the pallet.

Alternatively, the cam-controlled arm movement includes moving thecam-controlled arm to a first position aligned with the intermediateposition at a center height of the cam-controlled arm which is lowerthan the intermediate position; raising the cam-controlled arm to theintermediate position from first position to pick the molded sectionsfrom the robotic arm; moving the cam-controlled arm down from theintermediate position to the first position after picking the moldedsections; relocating the cam-controlled arm along the center height to asecond position aligned with the cam-arm pre-part release location;lowering the cam-controlled arm to the cam-arm part release location;raising a pallet from the cam-arm pre-part release location to thecam-arm part release location; and transferring the molded sections ontothe pallet. Illustratively, the relocating step further includesrotating the cam-controlled arm by approximately 180° around an axislongitudinal thereto.

Initializing the robotic and cam-controlled arms are performed, asneeded, to position them collision free zones.

With respect to the pallet that receives the molded articles fortransport to the inert chamber on the conveyor belt, the following stepsare performed:

raising the pallet from the cam-arm pre-part release location to thecam-arm part release location;

transferring the molded sections from the cam-controlled arm to thepallet; and

lowering the pallet containing the molded section from the cam-arm partrelease location to the cam-arm pre-part release location.

Prior to the pallet releasing step, the following steps may beperformed: actuating a pallet stop device to stop the pallet at thecam-arm pre-part release location; actuating a lift to raise the palletheld at the cam-arm pre-part release location by the pallet stop devicein order for the pallet to receive the molded articles from thecam-controlled arm; and actuating a pallet locate device to hold theraised pallet at the cam-arm release location.

Pallets may be held in a que upstream from the pallet that receives themolded articles from the cam-controlled arm located at the cam-armpre-part release location; and released one at a time to proceed to thecam-arm pre-part release location. Releasing these pallets in the queincludes actuating a cylinder that simultaneously releases a firstpallet in the que and holds a second pallet.

Alternatively two cylinders are used to release the pallets in the queone at a time. In this case, the following steps are performed:actuating a first cylinder which holds the first pallet located in theque; and actuating a second cylinder which releases the second palletlocated downstream from the first pallet.

In a racetrack mode, actuating the robotic arm transports the moldsections from the molding device to a discard bin for discarding themolded articles, while empty pallets move on the conveyor belt to theinert chamber. Similarly, in a sample mode, actuating the robotic armtransports the mold sections from the molding device to a sample palletlocated at the discard bin location, where the sample pallet is movedfrom a standby position to the discard location for receiving the moldsections from the robotic arm.

In another embodiment, whether a first pallet is located in a queposition of the conveyor belt is determined. When the first pallet islocated in the que position, then the robotic and cam-controlled armsare actuated.

BRIEF DESCRIPTION OF THE DRAWINGS

Further features and advantages of the invention will become morereadily apparent from a consideration of the following detaileddescription set forth with reference to the accompanying drawings, whichspecify and show preferred embodiments of the invention, wherein likeelements are designated by identical references throughout the drawings;and in which:

FIG. 1 illustrates a plan view of a front curve adapted to be removedand transported from a molding machine by an apparatus in accordancewith the present invention;

FIG. 2 illustrates a sectional view taken along line 2—2 in FIG. 1;

FIG. 3 illustrates a plan view of a base or back curve;

FIG. 4 illustrates a sectional view taken along line 4—4 in FIG. 3;

FIG. 5 illustrates a perspective view of a typical primary package basemember;

FIG. 6 illustrates a schematic plan view of a base curve transportapparatus according with the present invention;

FIG. 7 illustrates a diagrammatic perspective view of the apparatus ofFIG. 6 according with the present invention;

FIG. 8 illustrates movement of a robotic arm according with the presentinvention;

FIGS. 9, 10 and 11 illustrate, respectively, front, side and top viewsof a nesting arrangement for receiving base curves from a robotic armtransfer assembly shown in FIGS. 6 and 7;

FIG. 12 illustrates a flow chart of a robotic arm automatic sequence totransport base curves according with the present invention;

FIG. 13 illustrates movement of a rotary cam-controlled arm fortransporting base curve and primary package molds according with thepresent invention;

FIGS. 14 and 15 illustrate, respectively, top plan and side views of aconveyor system for receiving base curves from a cam-controlled transferassembly shown in FIGS. 6 and 7;

FIG. 16 illustrates a flow chart of a cam-controlled arm automaticsequence to transport base curves according with the present invention;

FIG. 17 illustrates a flow chart of an automatic sequence to transferbases and front curves according with the present invention;

FIGS. 18 and 19 illustrate, respectively, top and side views of theconveyor belt near a pallet pre-part release position according with thepresent invention;

FIG. 20 illustrates a flow chart of a Cambot home sequence for base andprimary package molds according with the present invention;

FIG. 21 illustrates a flow chart of a robotic arm home sequence for baseand primary package molds according with the present invention;

FIG. 22 illustrates a flow chart of an exposure timer sequence activatedin transferring base, front and primary package molds according with thepresent invention;

FIGS. 23-24 illustrates a flow chart of an parts sample sequenceaccording with the present invention;

FIG. 25 illustrates a schematic plan view of a front curve transportapparatus according with the present invention;

FIG. 26 illustrates a diagrammatic perspective view of the apparatus ofFIG. 25 according with the present invention;

FIG. 27 illustrates movement of a rotary cam-controlled arm fortransporting front curve molds according with the present invention;

FIG. 28 illustrates a flow chart of a robotic arm automatic sequence totransport front curves according with the present invention;

FIGS. 29 and 30 illustrate a flow chart of a cam-controlled armautomatic sequence to transport front curves according with the presentinvention;

FIG. 31 illustrates a flow chart of a Cambot home sequence for frontcurve mold sections according with the present invention;

FIG. 32 illustrates a flow chart of a robotic arm home sequence forfront curve mold sections according with the present invention;

FIG. 33 illustrates a schematic plan view of a primary package transportapparatus according with the present invention;

FIG. 34 illustrates a diagrammatic perspective view of the apparatus ofFIG. 33 according with the present invention;

FIGS. 35 and 36 illustrates plan views of a device for rearrangingarrays of the primary package molds received from a robotic arm transferassembly in a first orientation and adapted to be picked up by acam-controlled arm transfer assembly in a second orientation for furtherconveyance;

FIG. 37 illustrates a flow chart of a robotic arm automatic sequence totransport primary package molds according with the present invention;

FIGS. 38 and 39 illustrate a flow chart of a nest sequence to transferprimary package mold sections according with the present invention;

FIG. 40 illustrates a flow chart of a cam-controlled arm automaticsequence to transport primary package mold sections according with thepresent invention;

FIG. 41 illustrates a flow chart of an automatic sequence to transferprimary package mold sections according with the present invention;

FIG. 42 illustrates a flow chart of a racetrack mode sequence forprimary package mold sections according with the present invention; and

FIG. 43 illustrates a flow chart of a racetrack mode sequence for frontand back curve mold sections according with the present invention;

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Disclosed hereinbelow are embodiments of methods that relate to theremoval of molded articles which are used in the fabrication and/orpackaging of contact lenses, and which are transported at regularintervals from a molding installation to a first location, andthereafter to a second location for the subsequent disposition of thearticles, such as deposition onto pallets on a conveyor system forfurther treatment or processing. As such, the present applicationincorporates, by reference, the specification and disclosure of U.S.patent application Ser. No. 08/654,399, to Parnell et al., for“Apparatus And Method For Removing And Transporting Articles FromMolds”, which is a continuation-in-part of U.S. patent application Ser.No. 08/431,884, which is a continuation-in-part of U.S. patentapplication Ser. No. 08/258,267. In addition, U.S. patent applicationSer. No. 08/258,654 to Martin, et al. for “Consolidated Contact LensMolding” is also incorporates herein by reference.

The present invention is particularly suited for carrying out theabove-identified functions in the transporting of the molded articles inan improved manner and simpler mode than through the use of prior orcurrently employed devices and assemblies. For example, the presentinvention eliminates various programmable logic controllers (PLCs). Thiseliminates time needed for communication between the PLCS, thus reducingresponse time in processing the molded components, and quicklydetermining and discarding unacceptable molded components withoutdisrupting the continuous operation of assemblies, including upstreamand downstream assemblies.

Instead of the conventional PLCs, a supervisory microprocessor is usedfor multi-tasking. In addition, exposure time of the molded articles toair or oxygen is determine in series using a timer, for example, insteadof adding several partial exposure times counted by several timersassociated with the various conventional PLCs. This increases accuracyof exposure time and determination of overly exposed mold components forrejection. The timer may be implemented by hardware, or preferably bysoftware instruction to the supervisory processor, which may be amicroprocessor or a computer, for example. Thus, in contrast toconventional methods, the present invention increases speed of operationwhile preventing rejection of proper molded components that wererejected using conventional methods due to incorrect and inaccuratedetermination the exposure time.

The following descriptions, with references to the corresponding figuresas detailed hereinbelow, set forth the salient features and elements ofessentially three distinct but inventively interrelated embodiments ofthe present invention. The first embodiment is directed to the removalfrom a molding installation and transportation of back curve mold halvesfor the formation of ophthalmic or contact lenses. FIGS. 6-21 arerelated to the fabrication of back curve mold halves. The secondembodiment is directed to the removal and transportation of front curvemold halves which are designed to eventually mate with the back or basecurves mold halves. FIGS. 25-32 are related to the fabrication of frontcurve mold halves. The third embodiment is directed to the removal fromthe molding installation and transportation of molded contact lenspackaging elements, such as the base members for contact lens blisterpackages, referred to as primary packages. FIGS. 33-41 are related tothe fabrication of primary packages molds.

The process of fabricating contact lenses, in a manner regarding whichthe present invention is extremely useful, comprises creating a pair ofmold halves, between which a liquid monomer may be disposed, shaped intoa lens, and subsequently irradiated to prompt sufficient cross linkingto impart appropriate structural integrity to the lens. The mold halfsections which are used in creating the lenses are themselves molded;the molding process being especially intolerant of irregularities to theoptical perfection required of the surfaces. The mold sections arecreated in a rapid injection molding machine which produces amultiplicity of mold sections every 2.5 to 6 seconds, for example.

A molding machine 10, as illustrated diagrammatically in the variousdrawings, such as FIGS. 6-7, comprises two opposing elements 12, 14which interface to shape the back or front mold halves 20, 22, or theprimary package molds 30, shown in FIGS. 1-5. One of the two elements12, 14 has an array of regularly spaced concave recesses, while theopposing element has a corresponding array of convex protuberances, andwith concave recesses and convex protuberances defining, therebetween, ashaped volume for producing mold half sections 20, 22, or primarypackage molds 30, shown in FIGS. 1-5. A more detailed description of themolding machine, in conjunction with which the present invention isutilized, may be found in copending U.S. patent application Ser. No.8/257,785 for “Mold Halves and Molding Assembly for Making ContactLenses”, the disclosure of which is incorporated herein by reference.

In operation, first the opposing elements 12, 14 come together. Next,the material of the mold halves 20, 22 or the primary package molds 30,for example, molten polymer, is injected into the shaped volumes betweenthe surfaces of the opposing elements 12, 14. The mold halves 20, 22 orthe primary package molds 30 are held for a period of time sufficient toset their shapes.

FIGS. 1 to 4 show, respectively, front and base or back curve moldsections 20, 22 which are used in the manufacture of contact lenses.FIGS. 3 and 4 are top and side views, respectively, of a back curve moldsection 20. The back curve mold section 22 includes a central lensshaping curved portion 32, an annular flange portion 34, and a tab 36.

Because, in the case of the back curve, the central curved portion isused to form or shape the back curve or surface of a contact lens, it isdesirable to minimize direct contact therewith. Therefore, the flangeand tab portions 34, 36 are used to facilitate handling and positioningof the molded article. The simultaneous molding of the curve surfacewith the annular flange 34 and tab portions 36 has an additionalmanufacturing benefit in that it optimizes the injection moldingprocess.

Preferably, the base and front mold sections 20, 22 are each integrallymolded from a plastic material from the family of thermoplastics, suchas polystyrene or another suitable material. Illustratively, each moldsection 20, 22 has a thickness of 0.8 mm and 0.6 mm, respectively.Preferably, the thickness and rigidity of each mold section 20, 22 allowthe mold section to effectively transmit light and withstand pryingforces, which are applied to separate the mold sections from the mold inwhich those sections were made. The mold sections are also described indetail in the above-referenced copending U.S. patent application Ser.No. 08/257,758.

Once the shape of the base and front mold halves 20, 22, or of theprimary package 30, has been set, the opposing elements 12, 14 of themolding machine 10 (FIGS. 6-7) separate and the mold halves 20, 22, orthe primary package 30, are removed. The back curve mold half 20 isreferred to as such because it provides the convex optical mold surfacewhich shapes the portion of the contact lens which contacts the eye. Incontrast, the front curve mold half 22 is so called, because it providesthe concave optical surface which molds the front face of the lens.

In accordance with methods set forth to maintain optimal optical surfaceintegrity, the molding machine 10 which produces the back curve moldsections is designed specifically so that upon separation of elements 12and 14, the non-optically relevant, concave surfaces of the mold halvesare exposed (the convex surfaces remaining within the concave recesses).

While the molding machine 10′ (FIGS. 25-26) which produces the frontcurve mold sections 22 (FIGS. 1-2) each having portions 24, 26 and 28,which are analogous to portions 32, 34 and 36 of the back curve molds 20(FIGS. 3-4), is identical in nearly every functional aspect to theabove-described back curve mold half producing machine, when theopposing elements of the front curve molding machine separate, the frontcurve mold sections remain in contact with the convex protuberances.Once the opposing elements of the molding machines that produce theback, front and primary package molds have separated, then the moldedarticles may be removed.

The mold sections 20, 22 are used to ultimately produce the ophthalmicor contact lenses, whereas the base members 30 of blister packages, asshown by way of example in FIG. 5, provide the primary packaging for theformed contact lenses at some subsequent point during the productioncycle. The three embodiments that produce base (or back) and front moldhalves 20, 22, and the primary packaging mold 30 share many features,where various modifications thereof, are detailed hereinbelow. Threeembodiments of an apparatus for transporting the three mold section 20,22, 30 are described in detail in the above-mentioned U.S. patentapplication Ser. No. 08/654,399. A summary of the three machines isdescribed below as related to the present invention.

(A) Transportation of Base Curves

FIG. 6 shows a plan view of base curve mold section transportationapparatus 40 which is directed to the removal and non-damaging rapidtransport of the back curve contact lens mold halves 20 from a moldingmachine 10 to a remote location; for example, to a pallet transportableon a belt conveyor 50 of a contact lens fabrication assembly line, asdescribed further on herein.

More particularly, referring to the diagrammatic illustration of FIG. 6,the apparatus 40 includes first and second material handling assemblies42 and 44. The first assembly 42 is provided for removing the base curvemolded articles 20 from the molding machine 10, and transporting thearticles 20 to a first location at 46. The second assembly 44 ispositioned for receiving the molded articles 20 from the first assembly42 and transporting the articles from the first location 46 to a secondlocation 52.

A transport conveyor 50 is provided for receiving the articles 20 fromthe second assembly 44 at the second location 52 where, for example,pallets 54 are sequentially transportable on a conveyor belt 50. Thebase curve molded articles 20 are deposited on the pallets 54, so as toposition the articles 20 in recesses in the pallets 54, which arethereafter advanced to suitable installations, for instance, an inertchamber 58 for further processing or treatment. Illustratively, theinert chamber contains nitrogen.

FIG. 7 shows the base curve mold section transportation apparatus 40 ingreater detail. As shown in FIG. 7, the first assembly 42 is providedwith an arm member 60 which has one free end thereof equipped with aplate 62 having a vacuum head 64 for receiving the base curve moldedarticles 20 when the molding machine 10 has its elements 12, 14separate. The vacuum head 64 has an array of a plurality of articlepick-up cups 70 of a resilient material which communicate with a vacuumsource (not shown).

The molding machine elements 12, 14 move along arrow A in oppositedirection. An opening 66 is formed upon separation of the moldingmachine elements 12, 14, one of which contains the base curve moldedarticles 20. The opening 66 enables insertion therein of the vacuum head64.

As shown in FIG. 7, the plate 62 the first assembly 42 is in a verticalposition retracted from the opening 66. This is referred to as thewaiting position. Illustratively, the first assembly includes a sideentry robot SX-V3, made by Yushin corporation excluding the plate 62 andcontrol instructions, which are customized for different applications aswill become apparent. The SX-V3 42 is controlled by a central processor,such as a microprocessor or computer, for compound movement. As will bedescribed, the central processor also controls other aspects oftransferring the molded articles 20, 22, 30 from the molding machine tothe nitrogen chamber or other downstream processing stations.

FIG. 8 shows the movement of the SX-V3 42. Referring to FIGS. 7-8, theSX-V3 42 moves toward the opening 66 from its waiting position 68, whichis the position shown in FIG. 7. This movement is shown in FIG. 8 asreference numerals 1 and 2. Preferably, this movement is a compoundcurvilinear movement, shown as dotted line 1′, instead of two discreteorthogonal movements 1, 2. At the take out position 3, shown in FIG. 3,the plate 62 is positioned within the opening 66 located between the twomolding machine elements 12, 14, shown in FIG. 7.

The compound curvilinear movement 1′ of the SX-V3 robot is synchronizedwith opening of the molding device 10, to begins upon receiving a signalfrom molding machine 10 (FIG. 7) that its elements 12, 14 have separatedto form the opening 66 therebetween.

The compound curvilinear movement 1′ begins by accelerating the roboticarm 60 along the curvilinear path 1′ from the waiting position 68 to theopening 66 in the molding device 10, in accordance with accelerationparameters stored in a memory of the central processor.

After an acceleration time stored in the memory, the robotic arm 60decelerates where the robotic arm is approximately in the opening 66 ofthe molding device 10. This deceleration is according to decelerationparameters stored in the central processor memory. The decelerationprovides a damping effect for allowing smooth transfer of the moldsections from the molding machine to the robotic arm, with minimalvibration, thus ensuring the molded articles 20, 22, 30 do not fall offthe robots suction cups 70.

Upon pick up of base curve molded sections from one of the two moldingmachine elements 12, 14 by turning on the vacuum of the vacuum heads 64,the SX-V3 arm 60 retraces its movement, back toward its waiting position68, as shown by numeral 4, 5 in FIG. 8, which movement is a alsopreferably a compound curvilinear movement along the dotted line 1′.This reverse curvilinear motion along path 1′ from the molding machine10 to the robot SX-V3 waiting position 68 is also controlled by speed,acceleration, deceleration and time parameters stored in the memory, asdescribed above.

The movement of the SX-V3 or robotic arm 60 is programmable andcontrolled by the central processor, which controls various motors. Forexample as shown in FIG. 7, a drive motor 80 effectuates movement alongan axis C, which is transverse to the movement direction A of the twomolding machine elements 12, 14 along a conveyor belt 79; a kick motor84 effectuates movement along an axis B parallel to direction A along aroller and guide rail structure 85; and a rotary motor effectuatesrotary movement along an arrow D, through a rotary joint 88.

Control parameters are generated for each of the motors, which operatesimultaneously to provide movements in the three directions B, C and D,to effectuate the curvilinear motion 1′ (FIG. 8) of the SX-V3 roboticarm between the waiting position 68 and the opening 66 of the moldingdevice 10. Illustratively, the control parameters for each motor includeacceleration and deceleration parameters, and acceleration time anddeceleration time parameters.

Once the proper control parameters are generated, they are stored in thememory of the central processor. Illustratively, the proper controlparameters are generated by initially moving the SX-V3 robotic arm at aslow speed and generating a first set of control parameters. Thesecontrol parameters are adjusted as the speed of the SX-V3 robotic arm isincreased until the proper and optimal control parameters are generated,so that the SX-V3 robotic arm can move in and out of the molding machineopening 66 and pick up the molded articles smoothly.

Illustratively, the time that the SX-V3 robotic arm moves round tripbetween waiting position 68 and the opening 66 of the molding device 10is increased from 1.5 seconds (used to generates an initial set ofcontrol parameters) to its normal operating time of approximately 400 msto 800 ms. Preferably, the normal operating time is approximately 500 msand is programmable to other desired values. The speed of the SX-V3robotic arm varies from 0 to 1000 mm/sec, where its preferable operatingis approximately 800-850 mm/sec.

Illustratively, the acceleration and deceleration parameters rangeapproximately from 50% to 70% of full acceleration and deceleration. Inparticular, 70% of full acceleration and deceleration is used to movethe SX-V3 robotic arm in and out of the molding device opening 66, i.e.,between its waiting position 68 and the opening 66, as quickly aspossible. In moving the SX-V3 robotic arm between its waiting position68 and its parts release location 46, slower acceleration anddeceleration may be used, such as 50% of full acceleration anddeceleration.

After returning to the waiting position 68 with base curve moldedsections vacuum attached to the suction cups 70, the arm 60 by 90°rotate around an axis parallel and passing through the arm 60 alongdirection D. This rotate the plate 62 from the vertical direction, shownin FIG. 7, to a horizontal position facing down. The downwardly facingvacuum cups 70 hold the base curve molded sections by the suctioncreated by the applied vacuum. During the rotation along direction D,the arm 60 also moves around an axis 89, shown as dashed lines, which isperpendicular and passing through the rotary joint 88 along direction Efrom the waiting position 68 to the first location 46, also referred toas an SX-V3 parts release position, as shown in FIG. 8.

At the parts release location 46, the downwardly facing plate 62, havingthe base curve molded sections held thereon by vacuum, is in a verticalalignment above a pallet-shaped nest 90. The nest 90, as shown in FIGS.6, 7, and 9 to 11, is raised by means of a suitable hydraulic orpneumatic actuator 100 to cause recesses 92 formed in an upper surface94 therein to come into seating contact with the molded articles whichare located on the SX-V3 cups 70.

The vacuum in the cups 70 is then released and pressure generated toproduce a blow off of the articles which causes the molded articles tobe positioned in the recesses 92. Next, the nest 90 with the moldedarticles is lowered. This enables the arm member 60 to return to itsprevious position, as mentioned hereinbefore, to repeat the cycle ofremoving a successive batch of molded articles or base mold sections 20from the molding machine 10 in continuous repetitive sequences.

FIG. 12 shows a flow chart 102 of the SX-V3 automatic sequence for basecurves. The flow chart 102 describes a method for automatically andrapidly performing continuous repetitive steps, while keeping track ofoxygen or air exposure time of the base mold sections 20, beginning fromremoval thereof from the molding machine 10 to arrival thereof in thenitrogen chamber 58 shown in FIGS. 6-7.

As shown in step s10 of FIG. 12, the base curve automatic sequencemethod 102 starts by turning on an exposure time upon separation of thetwo molding machine elements 12, 14, which begins exposing the base moldsections 20 formed thereon to air. In step s12, the SX-V3 arm 60 movesfrom its waiting position 68 (FIG. 8), which is the position shown inFIG. 7, through movement 1 through 5, as described in connection withFIGS. 7-8, where the plate 62 removes base curve mold section 20 (FIGS.3-4) from the molding machine 10 and returns to its waiting position 68.

In step s14 of FIG. 12, and referring to FIG. 6, the central processorchecks whether a pallet 54 b is present in a que 250 (FIGS. 7, 18, 19)located on the conveyor belt 50. The pallet 54 b located at the que 250later advances to a Cambot pre-part release position 52 a for beingraised by lift 150 to the second position 52, also referred to as aCambot part release position 52 (FIG. 13), for receiving the base curvemold section 20, currently attached by vacuum suction on the SX-V3 plate62. Ascertaining whether a pallet 54 b is present in a que 250 isachieved by checking the status of a switch or sensor X15, which isactivated when a pallet 54 b is present in the que position 250, shownin FIGS. 7, 18 and 19. In the following flow charts, monitoring inputsare designated by an “X” followed by a particular numeral, while outputscausing performance of actions are designated by an “Y” followed by aspecific numeral.

In step s14 and referring to FIGS. 18-19, the presence of a pallet 54 bat the que 250 is ascertained instead of the presence of a pallet 54 aat the Cambot pre-parts release location 52 a. This prevents loss of anopportunity to transfer a set of molded articles to the pallet 54 a, atthe Cambot pre-parts release location 52 a. Otherwise, if the presenceof a pallet 54 a at the Cambot pre-parts release location 52 a isascertained, then a set of molded articles may have to be discarded dueto the high transfer speed, where the robot SX-V3 arm 60 moves at 1000mm/sec, for example.

If a pallet 54 b is not present in the que position 250, then path p16is followed to step s18 where the SX-V3 42 releases the base curve moldsection 20, which are attached to the SX-V3 suction cups 70, at a badpart position, shown in FIG. 6 as a rectangular element 96 having anopening therein which receives the bad part released from the SX-V3plate 62 and discards it through a tube 98. Preferably, a vacuum source(not shown) provides suction through the tube 98 for discarding thereleased bad part. As will become apparent, all three mold transferassemblies that transfer the base curve, front curve and primary packagemold sections 20, 22, 30, respectively, have the bad part releaseelement 96 which receives bad parts released from the SX-V3 plate 62 anddiscards them through the vacuum tube 98.

If a pallet 54 b (FIGS. 7, 18, 19) is present in the que position 250,then the base curve SX-V3 auto sequence 102 (FIG. 12) proceeds to steps19, where the central processor checks a sensor or limit switch (LS) X2to determine whether the nest 90 is in the low position. If the nest 90is not in the low position, to prevent the SX-V3 from colliding with thenest 90 which is in a high position, i.e., in the SX-V3 part releaseposition 46, then method 102 proceeds via path p20 to step s18 where theSX-V3 42 releases the base curve mold section 20 at the bad partposition 96. In addition, to prevent a collision between an up nest 90and the SX-V3 plate 62, stopping the SX-V3 at the bad parts position 96and releasing the base curve mold section 20 held on plate 62, allowscontinuous operation of the various assembly lines without interruption,where the SX-V3 returns to restart from step 10.

If the nest 90 is in the low position, the SX-V3 auto sequence 102proceeds to step s22, where the SX-V3 moves by movement 6, described inconnection with FIG. 8, where the SX-V3 arm 60 rotate in direction E,while simultaneously rotating 90° in direction D to position the plate62 in a horizontal direction facing downwardly over the lowered nest 90at the SX-V3 part release position 46.

In step s24, the central processor turns on switch Y1 to activate theactuator 100 (FIG. 10) to lift the nest 90 to the SX-V3 parts releaseposition 46 for contacting the base curve mold section 20 located on theSX-V3 suction cups 70. In step s26, the central processor checks todetermine that a nest up limit switch (LS) X1 is on, indicating that thenest 90 is in the up position. If the nest 90 is not in the up position,then path p28 is followed to step s30, where the transfer assembly 40 isshut down, including the molding machine 10, the SX-V3 robot 42 andCambot 44.

In step s30, a nest up sensor error message is displayed indicating thenest 90 has not yet reached its upper position at the SX-V3 partsrelease location 46. From step s30, path p32 returns the SXV3 autosequence 102 back to step s26, where the nest up LS X1 is checked again.If the nest never reaches its up position 46, then the SX-V3 autosequence 102 remains in the infinite loop defined by steps and pathss26, p28, s30, p32, where the entire transfer assembly 40 is shut down.At this point, corrective action is taken, e.g., by manual intervention.

During this infinite loop, if the nest 90 reaches its up position, thenthe transfer assembly 40 restarts and the SX-V3 auto sequence 102continues to execute step s34 after step s26. In this case, the nest upsensor is reset, e.g., by an operator, to clear the error messagedisplayed in step s30.

If after step s24, the nest 90 is in the up position then, the SX-V3auto sequence 102 continues to step s34 from step s26. In step s34, apart release timer T6 delays further processing for a predeterminedtime. The delay time is programmable and allows the nest 90 and theSX-V3 to be in the proper positions; where the nest 90 is the upposition and the SX-V3 is properly located over the nest 90, at theSX-V3 part release position 46.

Next, in step s36, the central processor turns off the vacuum of theSX-V3 that provides suction to the suction cups 70. The processorachieves this by turning off a vacuum switch Y117. Instead of vacuum,pressured air is introduced, by turning on an air blow switch Y118, toblow off the base curve molded sections 20 from the SX-V3 suction cups70 onto the nest 90.

In step s38, another delay timer, referred to as an after release timerT7, provides a programmable delay to allow the base curve moldedsections 20 to settle on the nest 90. Next, in step s40, the centralprocessor turns off the air blow switch Y118 to stop the flow ofpressurized air from the suction cups 70.

In step s42, the nest lift up switch Y1 is turned off to lower the nest90. When the nest 90 moves down to the low position, a nest low limitswitch (LS) X2 is activated, which is checked in step s44. In the nestlow LS X2 in not on, indicating the nest 90 has not reached its lowposition, then path p46 is followed to step s48. Step s48 is similar tostep s30, except that in step s48, a nest down sensor error message isdisplayed instead of the nest up sensor error message displayed in steps30. As in step s30, in step s48, the entire transfer assembly 40 isshut down until the nest lower limit switch X2 turns on.

If the nest low limit switch X2 is on, i.e., the nest 90 is in the lowposition, then in step s50 the SX-V3 arm 60 moves by movement 7 asdescribed in connection with FIG. 8, essentially being the reverse ofmovement 6, to return from the part release position 46 back to itswaiting position 68. The waiting position 68, shown in FIG. 8, is alsothe position of the SX-V3 42 as shown in FIG. 7, where the plate 62 inthe vertical position, ready for entry into the opening 66 of themolding machine 10 to remove another set of base curve mold sections 20,and repeat the above describe sequence 102, starting from step s10. TheSX-V3 arm 60 does not move until the nest 90 is lowered to prevent nearcollision therebetween.

After the nest 90 that has the base curve molded sections 20 thereon islowered, and the SX-V3 moves back to its waiting position 68 (FIG. 8) instep s50, and prior to repeating the base curve SX-V3 auto sequence 102by returning to the first step s10 thereof and starting the exposuretimer sequence, the second assembly 44, shown in FIGS. 6-7, is activatedin step s52 by turning on a Cambot run switch Y18.

The second assembly 44 essentially comprises a rotary parts handlingsystem, including a Cambot Rotary Parts Handler (registered trademark)manufactured by the Camco Corporation, which includes a rotatablecam-controlled member 110 which is also adapted to verticallyreciprocate in direction F, and which mounts an elongate arm member 112extending horizontally therefrom. The distal or free end of the armmember 112 has a head end plate 114 having an array of suction cups 116positioned thereon, as illustrated in FIGS. 6-7. The array of suctioncups 116 is in correlation with the spacing of the recesses 92 in nest90 (FIG. 11).

As shown in FIG. 7, the Cambot rotates in direction G, e.g., in ahorizontal plane around a vertical axis going through its pivoted end110, which is opposite the head end plate 114. Referring to the top planview of the transfer assembly 40 shown in FIG. 6, this Cambot rotationin direction G moves the Cambot arm 112 between horizontal and verticalpositions, as viewed from the top and shown in FIG. 6. Illustratively,the Cambot rotate by an angle of 90°, between the SX-V3 part releaselocation 46, where the nest 90 is located, and the Cambot pre-partrelease position 52 a on the conveyor belt 50 where a pallet 54 a isheld (by stop 252 shown in FIGS. 18, 19), waiting to be raised by lift150 (FIGS. 7, 13) to the Cambot part release position 52 for receivingbase curve molded sections 20 from the Cambot suction cups 116, afterbeing transferred thereon from the nest 90.

The Cambot arm 112 as shown in FIGS. 6-7 is in its home position locatedapproximately midway between the SX-V3 part release and Cambot partrelease positions 46, 52. Referring to FIG. 6, the Cambot arm 112 isapproximately in a horizontal direction when its head 114 is positionedover the nest 90 at the SX-V3 part release location 46, and in avertical direction when positioned over the Cambot pre-part releaseposition 52 a. The Cambot plate 114 faces downwardly and picks up basecurve molded sections 20 from the nest 90 by use of vacuum suction, froma vacuum source (not shown), through its suction cups 116, and releasesthe base curve molded sections 20 onto a pallet 54 a raised from theCambot pre-part release position 52 a to the Cambot part releaseposition 52 (FIG. 13). The base curve molded sections 20 are releasedfrom the Cambot suction cups 116 to the pallet 54 a by reversing theCambot vacuum to provide forced air to blow off the base curve moldedsections 20 onto pallet 54.

FIG. 13 shows movement of the Cambot 44, which moves, shown as movementc1 in FIG. 13, from its home position 104 toward the SX-V-3 partsrelease position 46. This movement c1 is essentially a rotary movementin the horizontal plane along direction G, shown in FIG. 7, which movesthe Cambot arm 112 to the horizontal position as viewed from the top andshown in FIG. 6, to vertically align the suction cups 116 with theircounterpart recesses 92 in the nest 90 that contains the molded articles20. The rotary arm member 112 is then lowered by the rotatable member110, shown in movement c2 in FIG. 13, so as to contact the moldedarticles 20 located on the nest 90, which is in a low position 46 a(FIG. 13), also referred to as a Cambot parts pick position. Forcomparison, SX-V3 movements 5 and 7 (FIG. 8) are shown in FIG. 13. Avacuum is applied to the suction cups 116 on the plate 114 of the armmember 112 so as to cause the suction cups 116 to engage the articles20.

The arm member 112 is then raised by the rotatable member 110, shown inmovement c3 in FIG. 13, and rotates through an angle of approximately90° in direction G (FIG. 7), shown as movement c4 in FIG. 13, so as toextend into a position, wherein the plate 114 with its suction cups 116retaining the molded articles is located above the conveyor belt 50,vertically aligned with the Cambot part release position 52, as shown inFIG. 13. As shown more specifically in FIGS. 14-15, the conveyor belt 50is adapted to be driven through the intermediary of a suitable motor118.

A plurality of pallets 54 each having an array of moldedarticle-receiving recesses 134 are positioned in contiguous sequence atan upstream position 136 relative to the Cambot arm member 112 of theCambot rotary part member 110 on the conveyor belt 50. The pallets 54are adapted to be individually advanced in spaced succession towards theCambot pre-part release position 52 a in synchronism with each pivotalmovement of the arm member 112 having the suction cups 116 holding anarray of molded articles 20 positioned over the conveyor belt 50, whicharticles 20 have been previously retrieved from the recesses 92 in thenest 90 located at the Cambot parts pick position 46 a.

As the pallets 54 are advanced, they are separated and individuallyforwarded by an indexing device a single pallet at one time, describedlater in connection with FIGS. 18-19, until a leading pallet 54 b in aque 250 is moved to the Cambot pre-part release position 52 a directlyin alignment below the arm member 112. The cam-controlled or Cambot arm112 is now pivoted over the conveyor 50 with the molded articles 20being held by the downwardly facing suction cups 116 over the leadpallet 54, also shown as pallet 54 a in FIGS. 18-19.

At that point, a lifting mechanism 150, shown in FIGS. 13-15, which maybe either hydraulic or pneumatic, is adapted to raise the pallet 54upwardly from the conveyor belt 50 to a predetermined extent, i.e., fromthe Cambot pre-part release position 52 a to the Cambot part releaseposition 52. After the lift 150 raises the pallet 54 a to the Cambotparts release position 52, the arm member 112 of the rotatablecam-controlled member 110 is displaced downwardly, as shown by movementc5 in FIG. 13, so as to enable the cups 116 to deposit the articles orbase curves 20 onto the facing recesses 134 formed in the pallet 54 a(FIG. 7). The base curves 20 are transferred from the Cambot suctioncups 116 to the pallet 54 a by releasing the vacuum in the cups 116 and,preferably, imparting a slight super-atmospheric pressure thereto, whichwill firmly push or blow off the base curves or articles 20 into therecesses 134 of the pallet 54 a, as shown in FIG. 7.

Next, the lift 150 is lowered to place the pallet 54 a back onto theconveyor belt 50 at the Cambot pre-part release position 52 a. At thistime, the Cambot arm 112 is raised, as shown by movement c6 in FIG. 13,and pivoted back towards the nest 90, shown as movement c7 in FIG. 13,to enable the pick-up of a subsequent batch of molded articles whichhave been deposited thereon by the SX-V3 42 as retrieved from themolding machine 10. Illustratively, as shown in FIG. 13, the up and downmovements c2, c3, c5, c6 of the Cambot is 3 inches, for example. FIG. 13also shows the SX-V3 42 and the nest 90 in a raised position at theSX-V3 parts release location 46, ready to receive the base curves 20from the SX-V3 42. The up and down movement of the nest 90 toward andaway from the SX-V3 arm 60 is approximately 4 inches, for example.

Upon receiving the base curve molds 20 and being lowered on conveyorbelt 50 at the Cambot pre-part release location 52 a, the lead pallet 54is advanced by the conveyor belt 50 so as to form a continuous line withpreceding base curve-filled pallets 54 which are then transported into asuitable chamber 58 containing, for example, a nitrogen atmosphere. Thiscycle is then continually repeated in the same manner of operation,rendering the entire apparatus and process of molded article transportextremely simple in comparison with currently employed material handlingsystems.

The Cambot run sequence is controlled by the central processor accordinga method 152 shown in FIG. 16. In step s52 of base curve SX-V3 autosequence 102 shown in FIG. 12, turning on switch Y18 by the centralprocessor begins the base curve Cambot run sequence 152 shown in FIG.16. As shown in FIG. 16, the Cambot run sequence 152 begins by turningon switch Y18 in step s54, which is the same as step s52 in FIG. 12.

In step s56 an internal timer for synchronization and fine tuning isturned on to delay further Cambot processing for a predetermined time,such as 0.5 seconds. In step s58, the Cambot movement is ascertained bychecking to see if the Cambot 44 has moved from its home position. Inparticular, if a Cambot home limit switch X19 is on, indicating that theCambot is still at its home position 104 (FIG. 13) and has not movedtherefrom, then path p60 is followed to step s62. The Cambot homeposition 104 is the position of the arm 112 shown in FIGS. 6-7 locatedapproximately midway the nest and Cambot parts release positions 46, 52(FIG. 13). At step s62, an error message indicating occurrence of aCambot start error is displayed, and a signal is sent to the centralprocessor of the SX-V3 to shut off the Cambot 44, until the operatorcorrects the error and restarts the system, for example.

If the Cambot has moved from its home position, thus turning off theCambot home limit switch X19, then in step s64 the Cambot vacuum isturned on. Next, in step s66, the central processor causes the Cambot tomove through movements c1 through c4, shown in FIG. 13; pick up the basecurves 20 located on the nest 90 at the Cambot parts pick position 46 a;and begin moving toward the Cambot parts release position 52 fortransferring the base curves 20 onto the pallet 54.

As the Cambot arm 112 approaches its home position 104 (FIG. 13), aCambot safety area limit switch X18 is activated, which indicates thatthe Cambot arm 112 is in a safe area which, referring to FIG. 6, is fromthe vertical Cambot arm position at the Cambot parts release position 52(FIG. 13) to a position slightly passed its home position 104. In thisCambot safe area, the Cambot 44 cannot collide with other movingelements, such as with the SX-V3 42, or with the nest 90 when raised tothe SX-V3 parts release location 46 for receiving the base curves 20from the SX-V3 suction cups 70.

If the Cambot safety area limit switch X18 is not on, indicating theCambot arm 112 has not moved far enough from the nest 90 toward theCambot parts release position 52, then path p70 is followed to return tothe beginning of step s68. When the Cambot arm 112 reaches the safetyarea, thus activating the Cambot safety area limit switch X18, executionis continued to step s72. In step s72, a Cambot vacuum verificationswitch X21 is checked for being in an on position, which indicates thatthe vacuum at the Cambot suction cups 116 is on, thus holding the basecurves 20 picked up from the nest 90. If the vacuum switch X21 is noton, then path p74 is followed to step s76, where an error message isdisplayed to alert an operator that the Cambot vacuum is off, requiringmanual intervention, for example, and resetting the system.

If the vacuum switch X21 is on, then in step s78, the Cambot continuesto the Cambot parts release position 52 (FIG. 13), through movements c4and c5 shown in FIG. 13, where the Cambot arm 112 is lowered to alignover a pallet 54, which is raised by lift 150 to receive the base curves20 from the Cambot suction cups 116 aligned with the pallet recesses 134(FIG. 14). After this alignment, in step s80, the Cambot turns off itsvacuum and turns on its blow off to transfer the base curves 20 onto theraised pallet 54.

After the base curves 20 are transferred to the pallet 54, the centralprocessor initiates a pallet sequence. The pallet sequence releases thepallet that contains the base curves 20 thereon. The released palletmoves on the conveyor belt 50 downstream and enters the nitrogen chamber58. In addition, the pallet sequence positions an empty pallet at theCambot pre-parts release location 52 a, by releasing the empty palletfrom the que 250 (FIGS. 7, 18, 19) located upstream from the Cambotpre-parts release location 52 a. FIG. 17 shows this pallet sequencewhich is referenced by numeral 154. Note, this pallet sequence 154 is anautomatic sequence that transfers the molded parts, the base curves 20in this case, from the Cambot suction cups 116 to pallets 54 located onthe conveyor belt 50. In addition to transferring base curve moldsections 22, this sequence 154 is equally applicable for transferringfront curve mold sections 22.

After step s80 in FIG. 16, the Cambot arm 112 is raised to begin itsreturn to the home position, which is the Cambot arm 112 position asshown in the top view of FIG. 6, where the Cambot arm 112 is locatedbetween the SX-V3 parts release and Cambot pre-parts release positions46, 52 a. The Cambot home position is referenced as numeral 104 in FIG.13. As shown in FIG. 13, the Cambot movement from the Cambot partsrelease position 52 back to its home position 104 is through movementsc6, c7.

In step s82, the central processor checks to status of the Cambot homelimit switch X19, similar to that in step s58. If this limit switch X19is not on, then path p84 is followed to return to the beginning of steps82. When the Cambot arm 112 reaches its home position, the limit switchX19 turns on and the Cambot run sequence 152 proceeds to step s86 whereit is terminated by turning off the Cambot run switch Y18. Thus, at endof the Cambot run sequence 152, the Cambot arm 112 is up raised andlocated at the home position 104 (FIG. 13).

As stated in describing step s80, the central processor initiates thepallet sequence 154 to cycle the pallets to move the pallet containingthe base curves 20 to the nitrogen tunnel or chamber 58 and positions anempty pallet from an upstream que to receive another set of base curves20 upon repeating the above mentioned methods. FIG. 17 shows the palletsequence 154.

In the first step of the pallet sequence 154, designated as references90 in FIG. 17, the central processor checks to ascertain that theCambot blow off switch is on, which switch was turned on in step s80shown in FIG. 16. If this switch is not on, then essentially furtherprocessing is delayed until the switch is actually turned on from thecommand given in step s80 of FIG. 16. Thus, path p92 is followed to thebeginning of the test step s90 when the Cambot blow off switch is noton.

The pallet cycle sequence 154 proceeds to step s94 when it is determinedin step s90 that the Cambot blow off switch is on, indicating air isblowing through the suction cups 116 of the Cambot plate 114 to transferthe base curves 20 to the pallet 54 which is raised by lift 150 to theCambot parts release position 52 (FIG. 13), while the Cambot arm islowered by movement c5 shown in FIG. 13.

In step s94, the pallet lift 150 up switch Y7 is turned off, thuslowering the pallet 54 which now contains thereon the base curves 20. Instep s96, an internal timer provides a programmable delay time, such as0.05 sec, to allow the lift 150 to completely lower the pallet 54. FIGS.18 and 19, which are provided to better understand cycling the pallets,are top and side views of the conveyor belt 50 near the Cambot pre-partsrelease position 52 a, showing the pallet que position 250 locatedupstream from the Cambot pre-parts release position 52 a and thenitrogen chamber 58 located downstream.

As shown in FIGS. 18-19, a pair of pallet stops 252 move toward or awayfrom each other using a hydraulic or pneumatic cylinder, for example. Inthe position near each other shown as solid line in FIG. 18, the palletstops 252 prevent a pallet 54 a, which is positioned at the Cambotpre-parts release location 52 a, from advancing downstream toward thenitrogen tunnel 58. When this pallet 54 a is raised by the lift 150(FIG. 19) from the Cambot pre-part release position 52 a (FIG. 13) tothe Cambot part release position 52 (FIG. 13), a pair of pallet locatecylinders 254 are actuated to move toward each other as shown by thesolid lines in FIG. 18. This holds the pallet 54 a as it is being raisedand lowered by the lift 150. The pallet locate cylinders 254 areactuated after the pallet 54 a is raised off the conveyor belt 50, toprevent the pallet locate cylinders 254 from engaging the conveyor belt50.

At the pallet que 250, two pallets 54 b, 54 c, are held by first andsecond pair of que stoppers 256, 258, respectively. Illustratively, inthe case of base and front curves 20, 22, the four pairs of hydraulic orpneumatic cylinders, namely, pallet stops 252, the pallet locatecylinders 254, and the first and second pair of que stoppers 256, 258,are individually controlled. By contrast, in the case of the primarypackages 30, the first and second pair of que stoppers 256, 258, arecollectively controlled by a single actuator or cylinder, referred to asan escapement cylinder.

Returning to FIG. 17, in step s98 a pallet locate forward switch Y9 isturned off to separate the pallet locate cylinders, as shown by thedotted cylinders 254 in FIG. 18. Next in step s100, the centralprocessor checks to determine if a down limit switch X14 of the liftstation 150 is on, indicating the lift station 150 is lowered to placethe pallet 54 a on the conveyor belt 50. This pallet 54 a contains thebase curves 20. If not, then path p102 is followed to the beginning ofstep s100 until the lift 150 is lowered to turn on the down limit switchX14.

At this point, the auto transfer sequence 154 of FIG. 17 progresses tostep s103 where a switch Y8 is turned on to move the pallet stops awayfrom each other, as shown by the dotted pallet stops 252 in FIG. 18.Since both the pallet stops 252 and locate cylinders 254 are in thedotted positions and separated from each other, and the lift 150 is low,conveyor belt 50 moves the pallet 54 a containing the base curves 20toward the nitrogen tunnel 58. Upon clearing the pallet stops 252, thepallet 54 a passes and activates a pallet index reset limit switch X13260. In step s104, the central processor checks to determine if thepallet index reset limit switch X13 260 is turned on. If not, then pathp105 is followed back to the beginning of step s104 until this switchX13 260 is turned on, which indicates that the pallets 54 a has clearedthe pallet stops 252.

Next in step s106, the switch Y8 is turned off to move the pallet stops252 toward each other, as shown by the solid lines 252 in FIG. 18. Instep s108, the inward position of the pallet stops 252 is ascertained byexamining the condition of a pallet stop return limit switch X16. Ifthis switch is on, indicating the pallet stops 252 have not yet returnedtoward each other, then path p110 is followed to the beginning of steps108 for retesting the state of the pallet stop return limit switch X16.

When pallet stops 252 move toward each other to block any pallets fromproceeding toward the nitrogen tunnel 58, thus turning off the palletstop return limit switch X16, then a que switch Y10 is turned on in steps112. This moves the second or upstream pair of que stoppers 258 towardeach other from its position shown as solid line in FIG. 18, to aposition shown as dashed lines for holding the upstream pallet 54 c andpreventing its movement. To allow enough time for the upstream questoppers 258 to move toward each other, a programmable delay isintroduced by counting an internal timer for 0.05 seconds, for example,in step s114.

Next in step s116, a que stopper return switch Y11 is activated by thecentral processor. This moves the first or downstream pair of questoppers 256 away from each other from its position shown as solid linein FIG. 18, to a position shown as dashed lines for releasing thedownstream pallet 54 b and allowing its movement downstream until it isstopped by the pallet stops 252, which have moved toward each otherduring step s106. A pallet in part position switch X11 is turned on whenthis pallet, which was released from the pallet que location 250, ispositioned at the Cambot pre-parts release location 52 a for receivingthe next set of base (or front)curves from the Cambot.

In step s118, the on position of the pallet in part position switch X11is ascertained. If the switch X11 is not on, indicating the pallet hasnot yet reached the Cambot pre-parts release location 52 a, then pathp120 is followed to return to the beginning of step s118 and retest theswitch X11. When a pallet reaches the Cambot pre-parts release location52 a and is stopped by the closed pallet stoppers 252, the switch X11turns on and the automatic pallet transfer sequence 154 continues tostep s122.

In step s122, the central processor turns off the que stopper returnswitch Y11, which was turned on in step s116. The off switch Y11 movesthe downstream pair of que stoppers 256 toward each other to prevent anypallets from proceeding further downstream. In step s124, which issimilar to step s114, a programmable delay is introduced by counting aninternal timer for 0.05 seconds, for example. This allows enough timefor the downstream que stoppers 256 to move toward each other.

In step s126, the central processor turns off the que switch Y10, whichwas turned on in step s112. The off switch Y10 moves the upstream questoppers 258 away from each other, thus releasing pallet 54 c andallowing it to move downstream until it is stopped by the downstream questoppers 256, which were moved toward each other in the previous twosteps s122, s124.

In step s128, the central processor turns on the pallet lift up switchY7, which was turned off in step s94. The on switch Y7 begins raisinglift 150, which raises the pallet now stopped by pallet stops 252, shownas reference 54 a in FIG. 18. Similar to steps s114, s124, in step s129,a programmable delay is introduced by counting an internal timer for0.05 seconds, for example. In step s130, the pallet locate forwardswitch Y9 is turned on, which switch Y9 was turned off in step s94. Theon switch Y9 moves the pallet locate cylinders 254 toward each other toclamp pallet 54 a, as shown by the solid cylinders 254 in FIG. 18.

Step s132 ascertains whether the pallet locate cylinders 254 have movedtoward each other and clamped the pallet 54 a, by confirming that apallet locate return limit switch X12 is off. If this switch X12 is notoff, then path p134 is followed back to the beginning of step s132. Whenthe switch X12 is off, the pallet transfer auto sequence 154 proceeds tostep s136, where the status of a lift station down limit switch X14 ischecked. If this switch X14 is not off, then path p138 is followed toreturn to the beginning of step s132, until the switch X14 turns off.The off switch X14 indicates that the lift 150, which was turned on tomove up in step s128, has moved up to raise the pallet 54 a from theCambot pre-parts release position 52 a to the Cambot parts releaseposition 52 (FIG. 13) for receiving the base curves 20 from the Cambot.

If the lift station down limit switch X14 is off, i.e., pallet 54 a israised by the lift 150, then the auto sequence 154 that transfers themolded parts, either base or front curves 20, 22 from the Cambot topallets located on the conveyor belt 50, is repeated by returning thebeginning of the sequence 154 at step s90.

FIG. 20 shows a Cambot home sequence or method 270, which is used toinitialize the Cambot 44 in a manual mode when necessary, for example,when power is interrupted or any of the auto sequences is stopped due toan error or alarm indication that requires operator intervention forcorrection thereof. Prior to commencing an auto sequence, the Cambotmust be in its home position, which is achieved by the Cambot homesequence 270. This Cambot home sequence 270 is identical for bothassemblies used for the manufacture of the base curve and primarypackage mold sections 20, 30 shown in FIGS. 1, 5, respectively

The Cambot home sequence 270 returns the Cambot to its home position104, shown in FIG. 13, where the Cambot arm 112 is raised and locatedapproximately midway between the nest 90 and the Cambot parts releaseposition 52. This Cambot home position is the location of the Cambot arm112 shown in FIGS. 6-7, and is the safe area where collision among thenest 90, the SX-V3 arm 60 and the Cambot arm 112 cannot occur.

As shown in FIG. 20, the Cambot manual mode home sequence 270 begins byproceeding to step s150, where, for example, an operator initiate thesequence by activating a start switch. Next in step s152, the centralprocessor checks to see if the nest up limit switch X1 is on, indicatingthat the nest 90 is in the up position. This step s152 is similar tostep s26 shown in FIG. 12. If the switch X1 is on, where the nest 90 isin the up position, then path p154 is followed, which returns the Cambotmanual mode home sequence 270 from step s152 to the beginning of steps150.

When the nest 90 is lowered, which turns off the switch X1, then theCambot home sequence 270 proceeds to step s156 and the status of anSX-V3 safety area limit switch X118 is checked. The safe area of theSX-V3 robot 42 is an area where the SX-V3 arm 60 is near the moldingapparatus 10, where the SX-V3 cannot collide with the nest 90 or theCambot arm 112. If the SX-V3 safety switch X118 is on, indicating theSX-V3 is not in the safe area, then path p158 is followed to step s160.

In step s160, the status of an SX-V3 flop area limit switch X119 ischecked by the central processor. Similar to the SX-V3 safe area, theSX-V3 flop area 305 is also an area where the SX-V3 42 cannot collidewith the nest 90 of the Cambot arm 112. However, instead of the SX-V3arm 60 being near the molding apparatus 10 as is the case for the SX-V3safe area, the SX-V3 flop area 305 is near the nest 90. If the SX-V3flop area limit switch X119 is on, indicating the SX-V3 is not in thesafe flop area, then path p162 is followed from step s160 to thebeginning of step s150.

If the SX-V3 flop area limit switch X119 is off, indicating that theSX-V3 is in a safe flop area, then path p164 is followed to step s166.Similarly, if the SX-V3 safety area limit switch X118 is off, indicatingthat the SX-V3 is in the safe area near the molding machine 10, then theCambot home sequence 270 proceeds from step s156 to step s166.

In step s166, which is similar to step s54 shown in FIG. 16, the Cambotrun switch Y18 is turned on. This cycles the Cambot through itsmovements c1-c7, shown in FIG. 13. In step s168, the central processorchecks the status of the Cambot home limit switch X19, similar to steps82 shown in FIG. 16. Path p170 is followed back to the beginning ofstep s168, until the Cambot reaches its home position 104 (FIG. 13), andturns on the Cambot home limit switch X19. At this point, the Cambothome sequence 270 proceeds to step s172, where the central processorturns off the Cambot run switch Y18. This positions the Cambot 44 at itshome position 104 (FIG. 13), which enable commencement of the variousauto sequences, and ends Cambot home sequence 270.

FIG. 21 shows an SX-V3 home or initialization sequence 275, where itslast step s198, returns the SX-V3 to its waiting position 68, shown inFIG. 8. In the first step s174 of the SX-V3 home sequence 275, thecentral processor turns of the nest lift up switch Y1, similar to thatperformed in step s42 of the SX-V3 auto sequence 102, shown in FIG. 12.This lowers the lift 150, thus lowering the nest 90.

Next in step s175, the central processor ascertains the status of thenest lift low limit switch X2, similar to that performed in step s44 ofthe SX-V3 auto sequence 102, shown in FIG. 12. If this switch X2 is off,then path p176 is followed and, in step s177, a message is displayedwhich is similar to that displayed in step s48 of the SX-V3 autosequence 102, shown in FIG. 12. At this point, for example, the centralprocessor turns off the base curve transfer assembly 40 awaiting errorcorrection by an operator.

If in step s175, the nest lift low limit switch X2 is on, then in steps178, the central processor ascertains the status of the Cambot homelimit switch X19, similar to step s82 of the Cambot run sequence 152,shown in FIG. 16. If the Cambot home limit switch X19 is off, indicatingthat the Cambot is not at its home position 104 (FIG. 13), then pathp179 is followed to step s180.

In step s180 of the SX-V3 home sequence 275 shown in FIG. 21, thecentral processor ascertains whether the SX-V3 is in the mold position,which is located in the opening 66 (FIG. 7) between the two moldingelements 12, 14 of the molding machine 10. If the SX-V3 is in the moldposition, indicating that it is safe to move the Cambot, then in steps190, the central processor turns on the Cambot run switch Y18.

In step s191, the central processor ascertains the status of the Cambothome limit switch X19. If this switch X19 is off, indicating the Cambotis not at its home position 104 (FIG. 13), then path p192 is followed torepeat step s191. When the Cambot home limit switch X19 is on,indicating the Cambot is at its home position 104 (FIG. 13), then instep s193, the central processor turns off the Cambot run switch Y18,thus stopping the Cambot at its home position 104. Next, the SX-V3 homesequence 275 continues to step 195.

Returning to step s180, if the SX-V3 is not in the mold position, thenpath p194 is followed back to step s194. Similarly, if in step s178, theCambot home limit switch X19 is on, indicating the Cambot is at its homeposition 104 (FIG. 13), then the SX-V3 home sequence 275 proceeds tostep s195. In step s195, the central processor ascertains the status ofa mold open signal X109. If this switch or signal X109 is off, then pathp196 is followed to step s197, and the central processor displays anappropriate error message. At this point, the central processor may alsoshut down the transfer assembly 40, which includes the molding machine10, the SX-V3 robot 42 and the Cambot 44 (FIG. 7), until the error iscorrect by an operator, for example.

If in step s195, the mold open signal X109 is on, indicating the twomolding element 12, 14 of the molding machine 10 (FIGS. 6-7) areseparated to form the opening 66, then the SX-V3 moves to its waitingposition 68, shown in FIG. 8. Note, the SX-V3 home sequence 275 isidentical for both the back curve mold sections 20 (FIG. 1) and theprimary package 30 (FIG. 5).

This completes the various sequences of transporting the base curves 20from the molding machine 10 to the nitrogen tunnel 58, which must beperformed rapidly, as measured by the exposure timer sequence initiatedat step s10 in the SX-V3 auto sequence 102 shown in FIG. 12.

FIG. 22 shows the exposure timer sequence 280 in detail, which isactivated in step s10 in the SX-V3 auto sequence 102 shown in FIG. 12.The exposure timer sequence 280 applies to the fabrication of both thebase and front curve mold sections 20, 22 (FIGS. 1-4), which aremanufactured by their two different respective devices 40 (FIGS. 6-7)and 40′ (FIGS. 25-26). In essence, the base and front curve moldedarticles 20, 22 are rejected and discarded upon exposure thereof tooxygen or air for a predetermined time, such as for 15 seconds or more.Note, it is not necessary to transfer the primary package mold sections30, shown in FIG. 5, to a nitrogen environment. Accordingly, theexposure timer sequence 280 of FIG. 22 is not applicable to the transferof the primary package mold section 30.

As shown in step s200 of FIG. 22, after the exposure timer sequence 280is activated in step s10 of FIG. 12, the central processor checks a moldclose limit switch X113 to determine if the two elements 12, 14 of themolding machine 10 (FIG. 7) are opened. If the mold close limit switchX113 is on, indicating that the molding machine elements 12, 14 areclosed, then path p202 is followed back to the beginning of step s200.When the molding machine elements 12, 14 open, which turns off the moldclose limit switch X113, then the exposure timer sequence 280 proceedsto step s204.

In step s204, the central processor starts to measure an exposure timer#1. Next in step s206, the central processor ascertains whether theSX-V3 42 is going to the bad part position to release a bad part in thebad part element 96 (FIG. 6). If the SX-V3 42 went to the bad partposition 96, then path p208 is followed to step s210, where the centralprocessor resets the exposure timer #1 and path p212 is followed back tothe beginning of step s200.

If the SX-V3 42 is not proceeding to the bad part position 96, then theexposure timer sequence 280 proceeds to step s214, where the centralprocessor checks the status of a pallet passed into nitrogen tunnelswitch X125. If this switch X125 is off, indicating that pallets 54 a(FIG. 18) has not passed into nitrogen tunnel 58, then path p216 isfollowed to step s218.

In step s218, the central processor checks whether the exposure timer #1has counted for over 13 seconds. If not, then path p220 is followed backto the beginning of step s214. If the exposure timer #1 has counted forover 13 seconds, then in step s222, the central processor checks whetherthe exposure timer #1 has counted for over 15 seconds. If not, then pathp224 is followed back to the beginning of step s214, through step s226.In step s226, a yellow patrol light is pulsed, by turning on switchY109, to warn of a possible bad part.

If the exposure timer #1 has counted for over 15 seconds in step s222,then path p228 is followed back to the beginning of step s214, throughsteps s230 and s226. In step s230, a red patrol light is pulsed, byturning on switch Y110, to warn of a bad part. Thus, when a bad part isdetected by having the exposure timer #1 count for over 15 seconds, thenboth the red and yellow lights are pulsed on. Illustratively, the yellowand red warning lights are located over the robotic SX-V3 assembly 42.Note, none of the manufacturing or transfer assemblies are turned offupon detection of an actual or possible bad parts. Rather, only one orboth yellow and red warning lights are flashed.

Returning to step s214, if the pallet passed into tunnel switch X125 ison, indicating that pallets 54 a (FIG. 18) did pass into nitrogen tunnel58, then the exposure timer sequence 280 proceeds to step s240. In steps240, the central processor checks whether the exposure times #1 hascounted for over 15 seconds. If not, the exposure timer sequence 280proceeds from step s240 to step s242. In step s242, switch Y28 is pulsedwhich pulses a signal that allows identification of good base or frontcurve molded articles 20, 22 that were exposed to air for less than 15seconds. Such identification may be tagging the pallet with a proper barcode, for example.

Next, the exposure timer sequence 280 proceeds from step s242 to steps210, where the exposure timer #1 is reset and path p212 is followed tothe beginning of the exposure timer sequence 280, ready for recyclingupon being started when the two molding elements 12, 14 of the moldingmachine 10 separate and expose the molded article to air, e.g., in steps10 of FIG. 12.

If the exposure timer #1 has counted for over 15 seconds, then path p244is followed from step s240 to step s210, where the exposure timer #1 isreset and the exposure timer sequence 280 complete a cycle by returningto its first step s200.

FIGS. 23-24 show steps associated with taking samples of the base curve,front curve, or primary package molded articles 20, 22, 30. FIG. 23 is aparts sample sequence 290 which begins in step s250 by ascertaining thestatus of a sample request button X124, also shown in FIG. 6. The samplerequest button X124 is activated when it is desired to collect samplemolded articles. In FIG. 6, numeral 240 is a pallet for collecting basecurve mold samples 20.

As shown in FIG. 23, if the sample request button X124 is not on, thenthe parts sample sequence 290 proceeds to step s252, which allows theSX-V3 to continue moving from the molding machine 10 toward the SX-V3parts release position 46. After step 252, the parts sample sequence 290returns to its beginning at step s250.

For the case of back curve or primary package molded articles 20, 30,they are released from the SX-V3 suction cups 70 onto the nest 90.However for the case of front curve molded articles 22, they arereleased from the SX-V3 suction cups 70 directly onto the Cambot, aswill be described in connection with FIGS. 25-27.

If the sample request button X124 is on, then path p254 is followed fromstep s250 to step s256 where a sample sequence 300 is initiated, whichis shown in detail in FIG. 24. After completion of step s256, the partssample sequence 290 returns to step s250.

As shown in FIG. 24, the sample sequence 300 begins in step s260 bymoving the SX-V3 to a flop position, after removing the molded articlesfrom the molding machine 10. The flop position is located a safedistance from the part reject position 96 and shown in FIG. 6 as numeral305. In this flop position 305, the SX-V3 plate 62 has rotated from itsvertical position to a horizontal position. In step s262, the centralprocessor stops the SX-V3 arm 60 at the flop location 305 when thesample request button X124 is activated, e.g., by an operator, in steps250 (FIG. 23). Steps s260, s262 are designated as sequence 1.

After activating the sample request button X124 in step s250 (FIG. 23),the sample pallet 240 is moved manually pushed by an operator, forexample, from its standby position, shown in FIG. 6, to the bad partrelease position 96. This must be done within one minute for continuedoperation. Otherwise, the SX-V3 is stopped and an error is indicated, aswill be described in connection with steps s264-s270.

Moving the sample pallet 240 to the bad part release position 96activates a sample pallet forward limit switch X32, where its status isascertained by the central processor in step s264. If this switch X32 isnot on, indicating there is no sample pallet 240 over the bad partsplate 96, then path p266 is followed to step s268. In step s268, thecentral processor checks whether the SX-V3 arm 60 has been in the flopposition 305 for more than 1 minute. If so, then in step s270, the backcurve transfer apparatus 40 is stopped and an alarm is activatedindicating that an error during sampling has occurred. Upon correctionof this error, the back curve transfer apparatus 40 is reinitializedprior to continuing its normal automatic cycle described above. Forexample, the SX-V3 and Cambot home sequences 270, 275, shown in FIGS. 20and 21, respectively, are performed. If the SX-V3 arm 60 has not been inthe flop position 305 for more than 1 minute, then path p272 is followedfrom step s268 back to step s264.

When the sample pallet 240 is moved to cover the bad parts plate 96,thus turning on the sample pallet forward limit switch X32, the samplesequence 300 proceeds from step s264 to step s274, where the SX-V3 movesto the reject position 96. Next in steps s276-s282, the samples arereleased from the SX-V3 suction cups 70 onto the sample pallet 240.Further, in steps s276, s280, before and after sample timers T4, T5 areactivated before and after the sample release step s278, respectively,In step s284, the SX-V3 42 returns to the flop position 305 afterreleasing the samples in step s278. Similar to step s262, in step s284,the SX-V3 42 stops at the flop position 305. Steps s274 to step s284 aredesignated as sequence 2.

Next, a similar-cycle is repeated twice to discard the next two sets ofarticles removed from the molding machine 10 as follows. The moldedarticles are discarded to allow time for sample collection, includingmoving the sample pallet between the standby and sample collect (ordiscard) positions 240, 96 (FIG. 6) while the transfer apparatus 40 iscontinuously operating. Thus, sample collection does not requireshutting down the transfer apparatus. Instead, few sets of moldedarticles are discarded until the sample pallet is moved back to itsstandby position 240 after collecting a sample from the sample ordiscard position 96. Note, although during the sample sequence 300 ofFIG. 24, two sets of molded articles are discarded, additional sets mayalso be discarded as needed for safe sample collection, for example,when the transfer apparatus is operating at higher speeds. Moreparticularly, in step s290, the SX-V3 returns to the molding machine 10and takes out another set of molded articles. The next step s292performs sequence 1, namely, steps s260, s262.

In step s294, the central processor ascertains the status of a samplesafe area limit switch X31, which is activated when the sample pallet ispulled back, e.g., by an operator, from the bad part release position 96to its standby position 240. When the sample safe area limit switch X31is not on, then path p296 is followed and steps s298, s300 are performedwhich are identical to steps s268, s270.

Thus if, within 1 minute, the sample safe area limit switch X31 is noton, i.e., if the sample pallet is not removed from the bad part releaseposition 96, then an appropriate sample release time out error messageis displayed in step s300 and the SX-V3 is shut down. Illustratively,the error indicates that the sample pallet is still in the bad partsrelease position 96, and is not yet pulled back to its standby position240.

If the sample pallet is removed from the bad part release position 96,thus turning on the sample safe area limit switch X31, then after steps294, sequence 2 is performed in step s302. Note, sequence 2 is stepss274 to steps s284. In step s302, the sample is released at a stepanalogous to step s278. This released sample 20, 22, or 30 is discardedthough tube 98, since the sample pallet 240 is no longer over the rejectposition 96, as ascertained in step s294. This sacrifices a set ofmolded articles, which may be front, base or primary package molds 20,22, or 30. The next two steps s304, s306 are identical to step s290,s292. After performing sequence 1 in step s306, the central processorascertains the status of the sample request button X124 in step s308, asalso performed in step s250 of the parts sample sequence 290, shown inFIG. 23.

When the sample request button X124 is not off, then path p310 isfollowed from step s308, and steps s312, s314 are performed which areidentical to steps s268, s270, as well as steps s298, s300. Thus if,within 1 minute, the sample request button X124 is not off, then anerror message, e.g., indicating that button X124 is not off, isdisplayed in step s314 and the SX-V3 is shut down.

If the sample request button X124 is off, then, after step s308,sequence 2 is repeated in step s316. Similar to step s302, another setof molded articles are sacrificed in step s316 by releasing them intothe tube 98. In the next step s318, the SX-V3 returns to its waitingposition, namely the position shown in FIG. 7, also shown as numeral 68in FIG. 8, where the SX-V3 plate 62 is in the vertical position. Thiscompletes. the sample sequence 300 as well as description of stepsassociated with handling the base curve molded articles 20, upon theirremoval from the molding machine 10.

A racetrack mode sequence will be described later in connection withFIGS. 42-43, where all the base curve molded articles 20 are rejected,i.e., removed from the molding machine 10 and released by the SX-V3 intothe bad parts release element 96 for discarding through the tube 98. Inthe racetrack mode, the pallets continue to move down the conveyor belt50 into the nitrogen tunnel 58 without containing any molded articles.

(B) Transport of Front Curves by Apparatus

FIGS. 25 and 26 show an apparatus used for transporting front curves 22of lens forming molds from another molding machine 10′, which is similarto the molding machine 10, shown in FIGS. 6-7, used for molding the basecurves 20. Elements in FIGS. 25-26, which are similar to their counterparts in FIGS. 6-7, are designated by a adding a prime to the elementsin FIGS. 6-7.

The front curve assembly 40′ (FIGS. 25-26) is basically identical indesign and function to the base curve assembly 40 (FIGS. 6-7), however,the nest 90 used with the base curve assembly 40 is dispensed with.Instead, after removal from the molding machine 10′, the front curve aredirectly transferred from the SX-V3 robot 42′ to the Cambot 44′ at theSX-V3 parts release location 46′.

As shown in FIG. 26, and unlike the base curve Cambot arm 112 (FIGS.6-7), the front curve Cambot arm 112′ rotates along its longitudinalaxis by 180° in direction H. This rotation H is during the Cambotmovement, in the horizontal plane, between its horizontal to verticalpositions as viewed from the top and shown in FIG. 25, where the frontcurves 22 are transferred from the SX-V3 suction cup 70′ to the Cambotsuction cup 116′, and then to a conveyor belt 160 for transport to thenitrogen tunnel 58. Note, two separate conveyor belts 160, 50 are shownin both FIGS. 6, 25 for transporting the front and base curves 22, 20,respectively.

Another difference between the back and front curve assemblies 40, 40′is that the front curve Cambot suction cups 116′ have a size and shapewhich are sightly different from the back curve Cambot suction cups 116.The front curve Cambot suction cups 116′ do not touch the critical innercurved side 24 (FIG. 1) of the front curve sections 22. Rather, thefront curve Cambot suction cups 116′ hold the front curve sections 22from its flanges 28, for example. The front curves 22 are removed fromthe molding machine 10′ in a converse orientation to that of the basecurves. Consequently, during their transport to the conveyor belt 160,the front curves 22 are inverted by 180° about their plane in directionH.

As the SX-V3 vacuum head 64′ is retracted from the mold elements 12′,14′, and rotated into horizontal orientation prior to reaching the SX-V3parts release location 46′, rather than the molded articles 22 beingdeposited onto a nest 90, as the base curves 20 are in the base curvetransport assembly 40 (FIGS. 6-7), this nest 90 is rendered redundantand consequently is eliminated together with its operative structure.

The arm 112′ of the front curve rotary parts handling system or Cambot44′, which has the rotatable and vertically reciprocable cam-controlledmember 110′, may be shorter in length than the back curve Cambot arm112. The front curve Cambot arm 112′ deposits the front curves 22 onpallets 54′ that travel on a conveyor belt 160 which is adapted to runin simultaneous operative parallel relationship with back curve conveyorbelt 50, shown in both FIG. 6, 25.

FIG. 27 shows movement of the Cambot 46′ where in its home position104′, the arm 112′ is horizontal to locate the plate 114′ at the SX-V3parts release position 46′, half way or at the center of its up and downrange of 3 inches. In the Cambot home position 104′, the Cambot plate114′ faces up. Cambot movement c1′ raises the plate 114′ up by 1.5inches from its home position 104′ to the SX-V3 parts release position46′, where the raised and up facing plate 114′ receives the front curvesfrom the SX-V3 suction cups 70′, which is rotated around direction D′ tobe in the horizontal direction.

After receiving the front curves 22, the Cambot moves down by 1.5inches, shown as movement c2′, rotates c3′ by 180° along direction H(FIG. 26). Now, the Cambot plate 114′ faces down. Next, the Cambot arm112′ moves by movement c4′ to a position which is vertical in regard tothe plan view shown in FIG. 25, to locate the downwardly facing plate114′ over a pallet 54′ located on the front curve conveyor belt 160.Instead of being sequential movements, the 180° head rotation (indirection H) and 90° arm rotation (in direction G) may be performedsimultaneously as a compound movement.

Next the Cambot is lowered (movement c5′ in FIG. 27) by 1.5 inches torelease the front curves 22 onto the pallet 54′. Thereafter, the Cambotretraces its steps back to the home position 104′ through movement c6′,which moves the plate 114′ 1.5 inches up; movements c7′, c8′ whichrotates head by 180° to face up and moves it to the home position 104′,1.5 inches below the SX-V3 parts release location 46′.

At the Cambot parts release location, which is also the Cambot partsrelease position 52′, the pallets are separated and advanced in sequenceas described in connection with FIGS. 18-19, where the leading pallet isthen raised by the lift 150 while in alignment with the Cambot plate114′, which is then moved downwardly and the vacuum released in cups116′ so as to enable the front curves to be received in the recesses134′ of the pallet 54′.

After the pallet 54 a located at the Cambot parts release position 52(FIG. 13) receives the front curves 22, the Cambot is raised 1.5 inches,and the lift 150 lowers the pallet 54 a ′ for advancing to the nitrogentunnel 58, as previously described in connection with FIGS. 18-19.

In essence, with the exception of the elimination of the nest 90 and therotatable nature of the front curve Cambot arm 112 about itslongitudinal axis so as to be able to invert the front curve molds 22,the function and sequence of operation is identical as with thatdescribed with respect to the base curve transports assembly 40 of FIGS.6-7.

FIG. 28 shows a flow chart 102′ of the SX-V3 automatic sequence forfront curves. Step s10′, s12′, s14′, s18′ of the front curves SX-V3 autosequence 102′ have identical counterparts shown as the same referencenumeral, but without the primes, in the base curves SX-V3 auto sequence102, shown in FIG. 12. Thus, in step s10′, the timer sequence 280 shownin FIG. 22 is started when the two molding machine elements 12′, 14′separate and air exposure of the front curves 22 begin. As described inconnection with the timer sequence 280 shown in FIG. 22, palletscontaining overexposed front curves, i.e., exposed to air for more than15 seconds, are identified as unacceptable for later discarding. In steps12′, the SX-V3 moves through movement 1-5 as described in connectionwith in FIG. 8.

In step s14′, the central processor check if the pallet in que switchX15 is on, i.e., whether a pallet 54′ is present in the position 250′ toeventually receive the front curve mold sections 22, currently attachedby vacuum suction on the SX-V3 suction cups 70′. Similar to that shownin FIGS. 18-19, if a pallet 54 b ′ is not present at the que position250′, i.e., switch X15 is off, then path p16′ is followed to step s18′where the SX-V3 42′ releases the front curve mold section 22 attached tothe SX-V3 suction cups 70′ at the bad part position 96′ (FIG. 24)attached to the discard vacuum tube 98′.

If a pallet 54 b ′ is present in the que position 250′, then after steps14′, the front curves SX-V3 auto sequence 102′ proceeds to step s350where the central processor ascertains the status of the Cambot homelimit switch X19. This step is similar to steps s58, s82 of the Cambotrun sequence 152 shown in FIG. 16. If the Cambot is not at it homeposition 104′ (FIG. 27), i.e., the Cambot home limit switch X19 is off,then path p352 is followed to step s18′.

If the Cambot is at it home position 104′ (FIG. 27), i.e., the Cambothome limit switch X19 is on, where the Cambot plate 114′ is facing upand is aligned in the SX-V3 part release location 46′, ready for movingup 1.5 inches to receive front curve molds 22 from the downwardly facingSX-V3 plate 62′, then in step s22′, the SX-V3 moves through movement 6(FIG. 8) to the SX-V3 part release location 46′. In step s34′, the partrelease fine tuning timer T6 delays processing as necessary for properalignment of the SX-V3 and Cambot suction cups 70′, 116′, at the SX-V3part release location 46′.

Next, the Cambot run switch Y18 is turned on to begin a front curveCambot run sequence 152′ that will be described in connection with FIGS.29-30. After the Cambot run switch Y18 is turned on, the Cambot beginsto move up 1.5 inches toward the SX-V3 part release location 46′. Whenthe Cambot moves up 1.5 inches, a Cambot upper limit switch X9 is turnedon. In step s354, the central processor ascertains the status of theCambot upper limit switch X9. If the Cambot upper limit switch X9 is noton, indicating the Cambot has not moved up by 1.5 inches, then path p356is followed to step s358 where an appropriate error message is displayedand the front curve assembly 40′ stops awaiting correction of the error,e.g., by manual intervention.

If the Cambot upper switch X9 is on, indicating the Cambot is up 1.5inches ready receive the front curve molds 22 from the SX-V3 suctioncups 70′, then in step s360, the Cambot run is stopped by turning offthe Cambot run switch Y18. The following three steps s36′, s38′, s40′are identical to step s36, s38, s40 in the back curve SX-V3 autosequence 102 shown in FIG. 12. More particular, in step s36′ the SX-V3vacuum is turned off and air is turned on to blow off the front curvesfrom the SX-V3 suction cups 70′ onto the Cambot suction cups 116′. Instep s38′, the after release timer T7 is turned on to introduce a properdelay that insures complete transfer of the front curve molds 22 fromthe SX-V3 42′ to the Cambot 44′. In step s40′, the SX-V3 blow off air isturned off and the Cambot drop 1.5 inches as shown in movement c2′ inFIG. 27.

Next, the front curve SX-V3 auto sequence 102′ proceeds to step s364,where the central processor ascertains the status of a Cambot lowerlimit switch X10. If this switch X10 in off, indicating the Cambot hasnot dropped 1.5 inches yet, then path p366 is followed to step s358where an appropriate message is displayed, and the front curve assembly40′ may be turned off awaiting error correction, e.g., through operatorintervention.

If the switch X10 in on, indicating the Cambot did drop by 1.5 inchesand it is safe for the SX-V3 to move, then in step s52′, the SX-V3 movesthrough movement 7, shown in FIG. 8, to its waiting position 68, and thefront curve SX-V3 auto sequence 102′ returns to its beginning step s10for recycling and repeating this sequence 102′.

The front curve Cambot run sequence 152′, shown in FIGS. 29-30 isdescribed next, which is similar to the back curve Cambot run sequence152 of FIG. 16. Steps s54′, s56′, s58′, s62′, s64′ have identicalcounterpart steps in the back curve Cambot run sequence 152 of FIG. 16.Accordingly, a description thereof is omitted here. From step s64′, thefront curve Cambot run sequence 152′ proceeds to step s380 where, as instep s354 of the front curve SX-V3 auto sequence 102′ of FIG. 28, thestatus of the Cambot upper limit switch X9 is ascertained. If thisswitch X9 is off, then path 382 is followed to step s384 where an errormessage is displayed. At this point, the front curve Cambot run sequence152′ returns to step s380.

If the Cambot upper limit switch X9 is on, indicating the Cambot israised 1.5 inches to receive the front curve molds 22 from the SX-V3suction cups 116′, then the Cambot run is turned off by turning off theCambot run switch Y18 in step s386. A fine tuning timer T16 is activatedin step s388 to provide a delay to allow the transfer of the front curvemolds 22 from the SX-V3 suction cups 70′ to the Cambot suction cups116′.

In step s400, where the Cambot suction cups 116′ has the front curvemolds 22 thereon held by vacuum, the Cambot run is turned on by turningon the Cambot run switch Y18. In step s402, the status of the Cambotlower limit switch is ascertained, similar to step s364 of the frontcurve SX-V3 auto sequence 102′ of FIG. 28. If this switch X10 is off,then the Cambot run sequence 152′ proceeds through path p404 to steps406, where an error message is displayed and the sequence returned tostep s402. At this point, for example, the front curve apparatus 40′ maybe stopped for manual intervention for error correction.

If this switch X10 is on indicating the Cambot dropped by 1.5 inches, asshown in movement c2′ in FIG. 27, thus it is safe to move the SX-V3 awayfrom the SX-V3 parts release position 46′, then in step s408 the Cambotrun switch Y18 is turned off until the SX-V3 moves to its waitingposition 68, shown in FIG. 8. In step s410, if the SX-V3 currentposition is not at its waiting position 68, then path p412 is followedto step s414.

In step s414, the central processor ascertain the status of an SX-V3flop area switch X119. If this switch X119 is on, indicating the SX-V3has not moved out of the way from its parts release area 46′ to its floparea 305′ (FIG. 24), then path p416 is followed to repeat step s410.Otherwise, if switch X119 is off indicating the SX-V3 has moved to theflop area 305′, then path p418 is followed to next step s420 of thefront curve Cambot run sequence 152′, shown in FIG. 30.

Returning to step s410, if the SX-V3 current position is at its waitingposition 68, then the front curve Cambot run sequence 152′ proceeds thestep s420 shown in FIG. 30. In step s420, now than the SX-V3 has movedaway from its parts release area 46′ to its flop area 305′, the Cambotrun switch Y18 is turned on. In step s422, a fine tuning timer T15 isturned on to introduce a delay in further processing to allow the Cambotto move to a safe area.

The remaining step in the front curve Cambot run sequence 152′ isidentical to the back curve Cambot run sequence 152, shown in FIG. 16.Thus for brevity, a detailed description of these steps s68′-s86′ isomitted, which were described in connection with steps s68-s86, shown inFIG. 16. During these steps s68′-s86′, the Cambot transfers the frontcurve molds 22 to the pallet 54′ and returns to the Cambot home position104′ shown in FIG. 27. At this point, the Cambot run is turned off instep s86′, where one cycle of the Cambot run sequence 152′ is completed,and the sequence 152′ returns to its beginning step s54′ (FIG. 29).

FIG. 30 shows a front curve Cambot home sequence 270′, which isidentical to the back curve and the primary package Cambot home sequence270, described in connection with FIG. 20, except step s152 in FIG. 20is deleted and not performed in the front curve Cambot home sequence270′ of FIG. 30. This is because the nest 90, shown in FIGS. 6-7 andused in the back curve assembly 40, is deleted from the front curveassembly 40′, shown in FIGS. 25-26. Accordingly, the detaileddescription of the back curve Cambot home sequence 270 of FIG. 20 isequally applicable to the front curve Cambot home sequence 270′ of FIG.31.

FIG. 32 shows a front curve SX-V3 initialization or home sequence 275′,which is similar to the back curve and the primary package SX-V3 homesequence 275, described in connection with FIG. 21. Comparing FIGS. 21and 32, it is seen that steps s174 and s175 of the back curve andprimary package sequence 275 (FIG. 21) are deleted in the front curvesequence 275′ shown in FIG. 32. That is, the front curve SX-V3 homesequence 275′ begins with step s178′, and ends with step s198′ similarto a description given in connection with the back curve and primarypackage sequence 275, shown in FIG. 21.

Additional steps s442, s446 and s448 are included in the front curveSX-V3 home sequence 275′. More particularly, if the SX-V3 in not in themold in step s180′, then path p440 is followed to step s442. In steps442, the central processor ascertains the status of the Cambot safelimit switch X18, as performed in step s68 of the back curve Cambot runsequence 152, shown in FIG. 16. If this switch X18 is off, then pathp444 is followed to step s446, where an appropriate error message isdisplayed and the front curve transfer assembly 40′ is shut down untilerror correction by manual intervention, for example.

If in step s442, the Cambot safe limit switch X18 in on, then the frontcurve SX-V3 home sequence 275′ continues to step s448. In step s448, thecentral processor ascertains the status of a Cambot rotate forwardswitch X7. If this switch X7 is off then path p450 is followed the steps446 where the error message is displayed. Otherwise, if the Cambotrotate forward switch X7 is on, indicating the Cambot arm 112′ isflipped to the up position in the direction of the SX-V3 plate 62′, thenthe front curve SX-V3 home sequence 275′ proceeds from step s448 to steps195′. Thereafter, the front curve SX-V3 home sequence 275′ proceedsfollowing identical steps as the back curve and primary package SX-V3home sequence 275′, shown in FIG. 21.

This completes description of sequences associated with handling thefront curve molded articles 22, upon their removal from the moldingmachine 10.

(C) Transportation of Primary Packaging Base Members

FIGS. 32 and 33 show an apparatus 40″ used for transporting primarypackaging base members 30 (FIG. 5) from another molding machine 10″,which is similar to the back and front curve molding machines 10, 10′,shown in FIGS. 6-7 and 25-26. Elements in FIGS. 33-34, which are similarto their counter parts in FIGS. 6-7 and 25-26, are designated by aadding a double prime to the elements in FIGS. 6-7.

As shown in FIG. 5, the base members 30 of the primary packages for thecontact lenses, for example, have a generally flat flange 180 and adepending tab 182 at one end thereof. A cavity 184 is molded in the flatflange 180 for receiving and sealingly storing a molded contact lenstherein while immersed in an isotonic saline solution.

As shown in FIG. 34, the SX-V3 plate 62″ has somewhat larger sized andspaced apart suction cups 70″ than corresponding plates used forretrieving base and front curve mold sections 20, 22. The SX-V3 42″moves through identical movements s1-s7 shown in FIG. 8 to removeprimary package molds from the molding machine 10″, by vacuum attachmentto the vertical plates 62″, and place the primary package molds 30 in ahorizontal orientation at the SX-V3 parts release location 46″.

Prior to pick up by the primary package Cambot 44″, the SX-V3 42″performs a set of movements 1-7, shown in FIG. 8. This places a set ofprimary package molds 30 onto a nest 90″ at the SX-V3 parts releaselocation 46″. Similar to the nest 90 of the base curve mold transferassembly 40 shown in FIG. 7, the nest 90″ is raised to receive theprimary package molds 30 from the SX-V3 suction cups 70″. Note, moldingmachine 10″ and SX-V3 suction cups 70″ hold a 4×4 array of primarypackage molds 30. Thus, the SX-V3 suction cups 70″ are arranged in a 4×4array. This is in contrast to the base curve and front curve moldingmachines and SX-V3 suction cups, where the array of base or front curvesections is a 2×4 array. The 4×4 array of primary package molds 30 maybe considered as two 2×4 arrays, shown as reference numerals 91″ and 91a ″ in FIGS. 34-36.

Similar to the SX-V3 4×4 array of suction cups 70″, the nest 90″ has anarray of recesses so as to be able to receive the 4×4 array of primarypackage or blister package base members 30 (FIG. 5), which are depositedin a single passe of the SX-V3 arm 60″ after removing them from themolding machine 10″. The two 2×4 primary package arrays 90″, 90 a″ arethen hydraulically or pneumatically re-spaced through various drives andcylinders, such as drive 213, shown in FIGS. 35, 36 by rotation about90° and repositioning, e.g., from two 2×4 arrays into a single 2×8array, in specific alignment so as to enable pick up by the Cabotsuction cups 116″ positioned on Cambot head plate 114″.

The Cambot 44″ transfers the 2×8 array of blister packages 30 from thenest 90″ to a pallet 54 a″ located in a Cambot parts release area 52″ ona conveyor belt 50″, as shown in FIGS. 34, 13, 18 and 19. This transferoccurs by moving the Cambot 44″ through movements c1-c7, which areidentical to movements of the base curve Cambot described in connectionwith FIG. 13. Note, a 2×8 array of blister packages 30 is beingtransferred, instead of a 2×4 array of back or front curve molds 20, 22,for example, the pallet 54″ and conveyor belt 50″ have a different sizefrom corresponding ones in the back and front curve transfer assemblies40, 40′ shown in FIGS. 6-7 and 25-26.

As described in connection with FIGS. 18-19, the pallets 54″sequentially advance along the conveyor belt 50″, which is alsomotor-driven by drive 118 in a manner similar to that described inconnection with FIGS. 14-15. The leading pallet 54 a″ is raised by lift150″ (FIG. 34) to the Cambot parts release location (which is similar tolocation 52 shown in FIG. 13), while the Cambot arm 112″ is lowered by 3inches, for example. The Cambot releases the vacuum in its cups 116″ andgenerates a slight super-atmospheric blow off condition so as to causethe molded articles 30 to be deposited onto recesses 134″ in the pallets54 a″ for further advance towards downstream processing stations. Note,unlike the base or front curves 20, 22, there is no need to transfer theprimary packages 30 to a nitrogen chamber. However, if desired anitrogen chamber may be included downstream from the primary packagetransfer assemble 40.

As with the base and front curve transfer assemblies 40, 40′, theprimary package assembly 40″ also enable taking samples using the samplepallet 240″, in an identical manner described in connection with FIGS.23-24.

FIG. 37 shows an SX-V3 automatic sequence 102″ for transfer of theprimary package base molds 30. The primary package SX-V3 auto sequence102″ has similar steps as the base and front curves SX-V3 auto sequences102, 102′, shown in FIGS. 12 and 28, respectively. However, in contrastto the base and front curves SX-V3 auto sequences 102, 102′, the primarypackage SX-V3 auto sequence 102″ has a cycle on demand loop, alsoreferred to as a standby mode, as will become apparent.

The primary package SX-V3 auto sequence 102″ begins by ascertaining thestatus of the pallet in que limit switch X15, in step s500, which issimilar to step s14 of the base curve SX-V3 auto sequence 102, shown inFIG. 12. If this switch X15 is off, indicating there is no pallet 54 b ″at the que location 250″ (FIG. 34), then the primary package transferapparatus 40″ is stopped, including the molding machine 10″, the SX-V3robot 42″ and the Cambot 44″, and path p502 is followed to step s504. Instep s504, a timer T10 is activated to stop processing if needed. Thisallows the pallet 54″ to reach the Cambot preparts release position 52a″.

If timer T10 has timed out in step s504, then path p506 is followed backthe step s500. The loop that includes step s500, path p502, step s504and path p506 back to step s500, is the cycle on demand loop, whereessentially the primary package transfer apparatus 40″ is stopped, untila pallet reaches the que location 250″ (FIG. 34). Although the primarypackage transfer apparatus 40″ is stopped during the cycle on demand orstandby loop, it is in a ready state to resume operation, when a palletreaches the que location 250″.

In this ready state, the SX-V3 is in its waiting position 68 (FIG. 8)ready to go into the molding machine 10″, which is stopped with its twoelements 12″, 14″ separated and holding a 4×4 array of primary packages30. Further, in the ready state, the Cambot is in its home position(which is similar to position 104 shown in FIG. 13); the nest 90″ isempty; and the pallet 54 a ″ is raised by lift 150″ to the Cambot partsrelease position (which is similar to position 52 shown in FIG. 13),ready to receive primary packages upon resumption of operation, whichoccurs when a pallet 54 b″ reaches the que position 250″ (FIG. 34).

When a pallet reaches the que location 250″, which turns on the palletin que limit switch X15. This turns on the primary package transferapparatus 40″ to resume operation, and allows the primary package SX-V3auto sequence 102″ to proceed from step s500 to step s12″.

Stopping operation of the primary package transfer apparatus 40″ andentering the standby mode, prevents fabrication of primary packages,which would otherwise be discarded, since there is no pallet on theconveyor belt 50″ to receive those primary packages. Thus, the cycle ondemand mode (which operates the primary package transfer apparatus 40″when a pallet reaches the que location 250″, and turns it off otherwise)prevents forming and discarding primary packages.

If timer T10 has not timed out in step s504, then the primary packageSX-V3 auto sequence 102″ proceeds to step s12″, which is also the stepperformed when the pallet in que limit switch X15 is on in step s500.

Steps s12″, s20″, s18″ are identical to counterpart step in the basecurve SX-V3 auto sequence 102 of FIG. 12. More particularly, in steps12″, the SX-V3 moves through movements 1-5, shown in FIG. 8, andremoves primary packages 30 from the molding machine 10″. In step s20″,the central processor ascertains the status of the nest lift down limitswitch X2. If it is off, indicating the nest 90″ is not down, then path16″ is followed and, in step s18″, the SX-V3 releases the primarypackages 30 at the bad parts position 96″ for discarding through thevacuum tube 98″, shown in FIG. 33. Next, the SX-V3 auto sequence 102″returns to its beginning at step s500.

If the nest lift down limit switch X2 is on, indicating the nest 90″ isdown, then in step s510, the central processor ascertains the status ofthe Cambot home limit switch X19. If this switch X19 is off, then pathp512 is followed to step s18″, where the SX-V3 releases the primarypackages 30 at the bad part position 96″ (FIG. 33) and returns to thebeginning of the sequence.

If the Cambot home limit switch X19 is on, indicating the nest 90″ isdown, indicating that the Cambot is at its home position 104 (FIG. 13),then in step s22″, the SX-V3 moves to the parts release position 46″through movement 6 described in connection with FIG. 8. Note, the Cambotis at its home position 104 is the Cambot arm 112″ position shown inFIGS. 33-34, approximately midway along the lateral direction G betweenthe SX-V3 parts release position 46″ and the Cambot parts releaseposition 52″.

After step s22″, where the SX-V3 is in the parts release position 46″, anest sequence 285 is executed in step s520. The nest sequence 285, aswill be described in connection with FIGS. 35-36, rotates and raises thenest 90″ for alignment with the SX-V3 suction cups 40″ at the SX-V3parts release position 46″. Next in step s26″, the central processorascertains the status of the nest lift up limit switch X1. If thisswitch X1 is off, then path p522 followed to return to step s26″ until.the nest is raised (due to execution of the nest sequence 285 in steps520) and the switch X1 turns on.

When the nest lift up limit switch X1 turns on, then in step s34″, adelay timer T6 is activated to provide a programmable delay as needed tohold the SX-V3 plate 62″ and the nest 90″ at the part release location46″. Next in step s36″, the vacuum of the SX-V3 cups 70″ is turned off,by turning off the vacuum switch Y117, and pressurized air is applied,by turning on the blow off switch Y118, to blow off the primary packages30 to the nest 90″, which is raised to receive them. In step s38″, theafter release timer T7 is activated to provide a programmable delayprior to turning off switch Y118 to turn off the SX-V3 pressurized air,as needed, for transferring the primary packages 30 from the SX-V3 tothe nest. In step s40″, the blow off air of the SX-V3, i.e., switchY118, is turned off.

The nest is lowered once it receives the primary packages 30 from theSX-V3. In step s524, the central processor ascertains the statues of thenest lift up limit switch X1, where path p526 is followed back to steps524, until this switch X1 turns off, indicating the nest is no longerin the up position. Next, in the s50″, the SX-V3 arm 60″ moves back toits waiting position 68 though movement 7, which is a compound movementthat includes rotation along direction D to position the SX-V3 plate 62″in a vertical position, for insertion into the opening 66″ of themolding machine 10″. This completes one cycle of the primary packageSX-V3 auto sequence 102″, which is repeated by returning to its firststep s500.

FIGS. 38-39 show the nest sequence 285, which is performed in step s520of the primary package SX-V3 auto sequence 102″, shown in FIG. 37. Thecentral processor starts the primary package nest sequence 285 byturning on the nest lift up switch Y1 to raise the nest 90″, similar tothat described in connection with step s24 in the SX-V3 base curve autosequence 102, shown in FIG. 12. Next in step s604, the central processorascertains the status of the nest lift up limit switch X1, as performedin step s12, shown in FIG. 12. If this switch X1 is not on, then pathp604 is followed to beginning of step s602.

When the nest lift up limit switch X1 in on, indicating the nest 90″ isin the upper position, then in step s606, a nest start timer T1 providesa programmable delay for the nest 90″ to remain in the raised positionfor receiving the primary packages 30.

After transfer of the primary packages to the nest 90″ using the SX-V342″, then in step s608, the nest lift up switch Y1 is turned off, thuslowering the nest 90. The following steps s610, s612, s614, s618, s620,s624, s626, s630, s634 activate three pairs of cylinders, e.g., 2″, 75mm and 10 mm cylinders, to rotate the primary packages from two 2×4arrays, shown in FIG. 35, to a single array of 2×8, as shown in FIG. 36.An additional pair of cylinders is also activated to re-space theprimary packages closer together. Note, the two inch cylinder is shownin FIGS. 35, 36 as reference numeral 213. The status of appropriateswitches are also checked during those steps to confirm that the primarypackages have been resized and re-spaced properly into a tightly packedsingle 2×8 array, which matches the suction cups 116″ of the primarypackage Cambot plate 114″ (FIG. 34).

In step s636, the central processor turns on the Cambot run switch Y18to activate a Cambot run sequence 152″, to be described in connectionwith FIG. 40, where the Cambot transfers the primary package from theSX-V3 parts release location 46″, contained on the nest 90″ to theCambot parts release location 52″ on the conveyor belt 50″.

In step s638, a nest return timer T12 provides a programmable delay, toallow the Cambot to pick up the primary packages from the nest 90″ andmove away therefrom. In steps s640 to s656, the cylinders returns to aposition to receive the next set of primary packages in the next cycle.

In step s660 shown in FIG. 39, which is the last step in primary packagenest sequence 285, the central processor ascertains that the Cambot hasmoved away from the nest toward its home position 104, shown in FIG. 13.When the Cambot home limit switch X19 is on, i.e., the Cambot is at itshome position 104 (FIG. 13) where it is safe to raise the nest 90″ up tothe SX-V3 parts release position 46″ (for receiving the next set ofprimary packages in the next cycle), then the nest sequence 285 repeatsitself by returning the step s600 (FIG. 38), and the nest 90″ is raisedto begin the next cycle.

FIG. 40 shows a primary package Cambot sequence 152″, which is identicalin every respect to the base curve Cambot sequence 152, shown in FIG.16, with an additional step s700. In Step s700, which is between stepss68″ and s72″, a vacuum verify timer T15 is activated to provide aprogrammable delay as needed.

FIG. 41 shows a primary package transfer auto sequence 154″, which isidentical in every respect to the base/front curves transfer autosequence 154, shown in FIG. 17, except that the following steps shown inFIG. 17 are deleted in FIG. 41; steps s114, s116, s122, s124.Accordingly, the description of the base/front curves transfer autosequence 154 (FIG. 17) is equally applicable to the primary packagetransfer auto sequence 154′ of FIG. 41.

FIGS. 42 and 43 show racetrack mode sequences 310, 310′, which areidentical except for their last steps, namely, step s810 shown in FIG.42, and step s812 shown in FIG. 43. FIG. 42 is the racetrack modesequence 310 for the primary package molds 30, and FIG. 43 is theracetrack mode sequence 310′ for the base and front curve molds 20, 22.In the racetrack mode, molded articles are not placed onto the pallets,for example, due to an error in the transfer assemblies 40, 40′, 40″.The racetrack mode is entered to prevent shut down of other assembliesassociated with the manufacture and packaging of contact lenses, forexample. Thus in the racetrack mode, the pallets continue to move downthe conveyor belt into downstream processing station without containingany molded articles.

In describing the racetrack mode, for brevity, the primary packageracetrack sequence 310, shown in FIG. 42 is described in associationwith the primary package transfer assembly 40″, shown in FIGS. 33-34, isreferred to. However, it is understood that the description is equallyapplicable to the back and front curve racetrack sequence 310′, shown inFIG. 43, associated with the back and front curve transfer assemblies40, 40′, shown in FIGS. 6-7 and FIGS. 25-26, respectively. In theracetrack mode first step s800 shown in FIG. 42, which has itscounterpart s800′ in FIG. 43, the SX-V3 moves to the reject position 96″and discards any molded articles carried on the SX-V3 suction cups 70″.

In step s802, the central processor turns off the pallet lift up switchY7, which lowers lift 150, shown in FIG. 19. In step s804, the palletlocate forward switch Y9 is turned off to separate the pallet locatecylinders 254 as shown by the dotted cylinders 254 in FIG. 18, anddescribed in connection with step s98 of the base and front curvetransfer auto sequence 154, shown in FIG. 17.

In step s806 the pallet step return switch Y8 is turned off to move thepallet stops 252 away from each other, as shown by the dotted stops 252in FIG. 18. Since both the pallet stops 252 and locate cylinders 254 areseparated from each other, as shown by the dotted positions in FIG. 18,and the lift 150 is low, the pallet are free to move from the Cambotpreparts release position 52 a to downstream processing stations.

In step s808, the que switch Y10 is turned on. As described inconnection with step s112 shown in FIG. 17, this moves the upstream questoppers 258 toward each other from its position shown as solid lines inFIG. 18, to a position shown as dashed lines for holding the upstreampallet 54 c and preventing its movement. In step s810, the centralprocessor turns on a que lift up switch Y11. This flips both thedownstream and upstream que stoppers 256, 258 out of the way so thatpallet can move downstream on the conveyor belt without hindrance.

As stated, the only difference between the two racetrack mode sequences310, 310′ is the last step. Comparing the two last steps s810, s812,shown in FIGS. 42-43, indicates the same switch Y11 is activated.However, as described in the previous paragraph in connection with steps810, this switch Y11 is the que lift up switch. In contrast for thecase of base and front curves transfer assemblies, switch Y11 is the questopper return switch described in connection with step s116 (and steps122) of the base and front curves transfer auto sequence 154, shown inFIG. 17. Similar to step s116 (FIG. 17), the last step s812 of the baseand front curves racetrack sequence 310′, the central processor turns onthe que stopper return switch Y11 to release the downstream pallet 54 bin the que shown in FIG. 18, where the downstream que stoppers 256 aremoved away from each other, shown by the dashed lines.

Alternatively in step s808′, instead of turning on the que switch Y10 tohold the upstream pallet 54 c (FIG. 13), this switch Y10 is turned offin step s808′. This releases the upstream pallet 54 c, and upon releaseof the downstream pallet 54 b, the pallets move downstream unhindered,similar to the pallet unhindered movement in the primary packageassembly 40″, as described in connection with step s810 of the primarypackage racetrack sequence 310 (FIG. 39).

From the foregoing, it becomes readily apparent that the presentinvention is a simplified automatic method that increases speed ofoperation of assemblies for transferring and transporting of highquality molded articles. The increased speed, as well as better andfaster synchronization and communication among the various assemblies isachieved by the central processor that replacing various programmablelogic controllers (PLCs). This provides fast and smooth transfer of themolded articles among the various assemblies, and minimizes vibrationwhich would exert a deleterious effect on the quality of the articlesbeing produced.

In addition, the computer controlled method provides flexibility in finetuning and modifying the various steps as needed, with minimal or nohardware changes. Rather, instructions executed by the computer arechanged to modify desired steps. In addition, the computer controlledmethod allows use of state of the art components, such as incrementalencoders that provide exact location of the SX-V3 robotic arm, forexample, servo motors that precisely move various elements to desiredlocations. In addition, closed loop control circuits may be used toincrease accuracy and stability of various steps, such as stepsinvolving transfer and movement.

While there has been shown and described what are considered to bepreferred embodiments of the invention, it will, of course, beunderstood that various modifications and changes in form or detailcould readily be made without departing from the spirit of theinvention. It is, therefore, intended that the invention be not limitedto the exact form and detail herein shown and described, nor to anythingless than the whole of the invention herein disclosed as hereinafterclaimed.

What is claimed is:
 1. A central supervisory processor controlled cycleon demand method for removing and transporting mold sections forfabricating ophthalmic lenses from a molding device to pallets locatedon a conveyor belt for transporting downstream to processing stationscomprising the steps of: opening the molding device and exposing themold sections; determining whether a first pallet is located in a queueposition of the conveyor belt; when said first pallet is located in thequeue position, actuating robotic and cam-controlled arms under controlof said central supervisory processor, said robotic arm transporting themold sections from the molding device to an intermediate position, andsaid cam-controlled arm transporting the mold sections from theintermediate position to a second pallet held on a conveyor belt at acam-arm pre-part release location; and releasing said second pallet heldat the cam-arm pre-part release location to move downstream on theconveyor belt to the processing stations.
 2. The cycle on demand methodof claim 1 further comprising, when said first pallet is not located inthe queue position, stopping operation of said molding device and saidrobotic and cam-controlled arms; wherein said molding device is stoppedin an open position containing the mold sections, and said robotic armis stopped in a waiting position ready to enter the molding device uponresumption of operation; said stopped molding device and said stoppedrobotic and cam-controlled arms being ready to resume operation whensaid first pallet reaches the queue position.
 3. A central supervisoryprocessor controlled method for removing mold sections for fabricatingophthalmic lenses from a molding device comprising the steps of: openingthe molding device and exposing the mold sections; staring a timer uponopening the molding device and exposing the mold sections tocontinuously measure exposure time of the mold sections; accelerating arobotic arm under control of the central supervisory processor along acurvilinear path from a waiting position to an opening in the moldingdevice in synchronism with the opening of the molding device, inaccordance with predetermined control parameters for a plurality ofmotors stored in a memory of the central supervisory processor toeffectuate a curvilinear motion of the robotic arm between the waitingposition and the opening of the molding device; and decelerating therobotic arm under control of the central supervisory processor when therobotic arm is approximately in the opening of the molding device, toprovide a damping effect for allowing transfer of the mold sections fromthe molding machine to the robotic arm.
 4. The method of claim 3,wherein the control parameters for each of said plurality of motorsinclude acceleration and deceleration parameters, and acceleration anddeceleration time parameters.
 5. The method of claim 3, wherein thecurvilinear path includes an optimal trajectory path of the robotic armbetween the waiting position and the opening of the molding device, toposition the robotic arm at the opening of the molding device toretrieve the exposed mold sections as the molding device opens.
 6. Themethod of claim 3, the method further including: synchronizing with thestep of opening of the molding device to begin the step of acceleratingto enable positioning of the robotic arm at the opening of the moldingdevice in an optimal amount of time.
 7. The method of claim 3, furthercomprising identifying molded articles as unacceptable when the timemeasured by the timer exceeds a predetermined time.